Base and solvent-decomposed thermosetting molding with aliphatic polyester

ABSTRACT

The thermosetting composition of the present invention includes an unsaturated polyester, an addition polymerizable monomer, a low shrink agent other than an aliphatic polyester, and an aliphatic polyester decomposed in a decomposing solution containing from about 0.1 to about 50% by weight of at least one base selected from the group consisting of alkali metal hydroxides, alkaline earth metal hydroxides, alkali metal oxides, alkaline earth metal oxides, alkali metal alkoxides and alkaline earth metal alkoxides, and at least one solvent selected from the group consisting of water, methanol, ethanol, and ethylene glycol at a temperature lower than a boiling point of the decomposing solution after being cured.

TECHNICAL FIELD

The present invention relates to a thermosetting composition withsuperior strength and heat resistance, readily decomposed, a moldingcompound containing the composition, a molded structure using themolding compound, and a method for decomposing the composition, themolding compound, and the molded structure.

BACKGROUND ART

Conventionally, thermosetting resins have been widely utilized forindustrial materials. The volume of production of the thermosettingresins has increased at a rate of several percent per annum since 1985,and reached about 2,000,000 tons during the full year of 1990. Examplesof the thermosetting resins include an epoxy resin, a phenol resin, apolyurethane resin, an unsaturated polyester resin, a urea resin, amelamine resin, and a polyimide resin. Such thermosetting resins mostlyfind their application in composite materials containing a filler, suchas fiber reinforced plastics (FRP). For example, about 80% of producedunsaturated polyester resins have been used as FRP. In addition to glassfibers, examples of fillers contained in the composite materials includeinorganic materials such as calcium carbonate, talc, and silica, andorganic materials such as pulp and wood. Since the thermosetting resinsare readily reinforced by being composited with a filler or the like,they have widely been used for consumer products or for industrialproducts such as materials for molding, multilayer plates, adhesives,and coatings.

When being cured, the thermosetting resins have a three-dimensionalcross-linked structure and generally assume an insoluble and infusiblesolid form, so that they are difficult to be decomposed for disposal.Thus, the thermosetting resins have conventionally been junked becauseof their difficulty in reproduction and recycling.

However, in recent years, waste problems have received heightenedattention, and the decomposition and reproduction of waste resins havebeen recognized as serious problems. Such problems are also importantwith respect to the thermosetting resins. For example, fiber reinforcedunsaturated polyesters have been used a lot for producing large productssuch as a fishing boat, a tank, and housing equipment, causing seriousproblems of decomposition and recycling of waste. This necessitatestechnical development for minimizing the volume of waste thermosettingresins and recycling thereof. As a result, the technique for thermallydecomposing the waste thermosetting resins into raw materials has beenstudied. However, the thermosetting resins are technically difficult tobe decomposed for disposal, because of their properties such ashardness, strength, heat resistance, frame resistance, and chemicalresistance. Furthermore, the thermosetting resins are mostly used asstructural materials because of their outstanding strength; for example,they are used for molding compounds for motors. In this case, theresulting waste thermosetting resins may include other materials such asmetal. Such materials as metal are more expensive than the thermosettingresins. As is understood from this fact, there arises a serious problemthat less expensive waste resins have prevented the expensive materialssuch as metal from being reproduced or recycled. Thus, waste problemswith respect to the thermosetting resins cannot be dissolved by usingconventionally available resins or by using conventional methods fordecomposing for disposal.

On the other hand, in recent years, molded structures obtained byintegrally molding a molding compound made of a thermosetting resin,such as molded motors, molded transformers, and IC packages have beenused in consumer, industrial, and paperwork equipment, and the like.Hereinafter, an example of the molded motor will be described. Suchmolded motors have outstanding properties in terms of noise, damping,insulation, and maintenance, and their compact size facilitates theautomation thereof. Because of these properties, the demand for moldedmotors has rapidly increased.

Conventionally used molded stators of molded motors used as AC motors,brushless DC motors, etc. generally have a structure disclosed, forexample, in Japanese Laid-Open Patent Publication No. 61-214740. Such astructure will be described with reference to FIGS. 7 and 8. FIG. 7 is aperspective view showing an external appearance of a molded motor with aconventional molded stator 201; FIG. 8 is a perspective view showing astructure of a stator portion before being molded. As shown in FIG. 7,the molded motor includes a motor portion 220 and the molded stator 201integrally molded so that the stator portion of FIG. 8 is covered with amolding compound 202. The stator portion, as shown in FIG. 8, has a coil203, an iron core 204, and an insulator 207. The insulator 207 has aprinted board 211 with a coil pattern 210 at one part thereof. On theprinted board 211, end portions of the coil 203 are connected to leads212 so that a signal is input to the coil 203 through the end portionsthereof. The molding compound 202 contains, as a binder, a thermoplasticresin such as polyethyleneterephthalate, polyethylene, polypropylene andnylon, or a thermosetting resin such as an unsaturated polyester, avinyl ester resin and a phenol resin, and contains, as an additive,calcium carbonate, talc, or carbon black.

At the disposal of the molded motor, it is desired that the moldingcompound 202 is removed from the molded motor, and the remaining metalssuch as the iron core 204 and the coil 203 are recycled. According tothe conventional waste disposal, the molding compound is first shreddedwith a shredder, and the iron core and the coil are picked up from theshredded molding compounds for recycling. However, the molded motors asdescribed above are likely to damage the teeth of the shredder withtheir iron cores and/or the coils. This stands in the way of disposingof such molded motors and results in having to bury the molded motorstogether with the iron cores and the coils in the land. The moldingcompounds as described above are not naturally decomposed while beingburied in the land, so that silicon steel plates and copper wires usedfor the iron cores and the coils remain buried without being recycled,even though they still keep great value after being used. Furthermore,the thermosetting resins used as the molding compounds cannot be subjectto the conventional decomposing method, such as a method for minimizingthe volume of waste thermosetting resins by thermal decomposition. Thus,the conventional molded motors have problems that they cannot bedisposed by shredding or decomposing the molding compounds, and valuablethings such as the iron cores and the coils cannot be kept for recyclingat the time of the disposal of the molded motors. Other moldedstructures such as molded transformers also have the same problems asthe above.

As described above, considering the decomposition of large waste resinsfor disposal and the recycling of expensive materials such as metalsincluded in molded motors, there is a strong demand for thermosettingresins or thermosetting compositions, which can retain outstandingconventional characteristics and can be readily decomposed.

DISCLOSURE OF INVENTION

A first thermosetting composition of the present invention includes athermosetting resin and an aliphatic polyester, wherein decomposition ofthe thermosetting composition is promoted by decomposition of thealiphatic polyester in a decomposing solution containing at least a baseafter the thermosetting composition is cured.

A second thermosetting composition of the present invention includes anunsaturated polyester, an addition polymerizable monomer, a low shrinkagent other than an aliphatic polyester, and an aliphatic polyester, andis capable of being readily decomposed in a decomposing solutioncontaining a base and at least one solvent selected from the groupconsisting of water, methanol, ethanol, and ethylene glycol at atemperature lower than a boiling point of the decomposing solution afterbeing cured.

A third thermosetting composition of the present invention includes anunsaturated polyester, an addition polymerizable monomer, andpolycaprolactone, and is capable of being readily decomposed in adecomposing solution containing a base and at least one solvent selectedfrom the group consisting of water, methanol, ethanol, and ethyleneglycol at a temperature lower than a boiling point of the decomposingsolution after being cured.

In a preferred embodiment, at least part of the addition polymerizablemonomer is an aliphatic polyester having an addition polymerizableterminal.

A fourth thermosetting composition of the present invention includes analiphatic polyester, and a phenol resin or an epoxy resin, and iscapable of being readily decomposed in a decomposing solution containinga base and at least one solvent selected from the group consisting ofwater, methanol, ethanol, and ethylene glycol at a temperature lowerthan a boiling point of the decomposing solution after being cured.

In a preferred embodiment, the aliphatic polyester contained in thefirst, second, and fourth thermosetting compositions is at least onealiphatic polyester selected from the group consisting ofpolycaprolactone, polypropiolactone, polyglycolic acid, polylactic acid,polyethylene adipate, polybutylene adipate, polytetramethylene adipate,polyethylene succinate, polybutylene succinate, polycaprolactonediol,polycaprolactonetriol, and poly(3-hydroxyalcanoate); and the thirdthermosetting composition further contains such aliphatic polyestersother than polycaprolactone.

A first molding compound of the present invention includes as a binder athermosetting composition containing a thermosetting resin and analiphatic polyester, wherein decomposition of the thermosettingcomposition is promoted by decomposition of the aliphatic polyester in adecomposing solution containing at least a base after the thermosettingcomposition is cured.

A second molding compound of the present invention includes as a bindera thermosetting composition containing an unsaturated polyester, anaddition polymerizable monomer, a low shrink agent other than analiphatic polyester, and an aliphatic polyester, wherein thethermosetting composition is capable of being readily decomposed in adecomposing solution containing a base and at least one solvent selectedfrom the group consisting of water, methanol, ethanol, and ethyleneglycol at a temperature lower than a boiling point of the decomposingsolution after being cured.

A third molding compound of the present invention includes as a binder athermosetting composition containing an unsaturated polyester, anaddition polymerizable monomer, and polycaprolactone, wherein thethermosetting composition is capable of being readily decomposed in adecomposing solution containing a base and at least one solvent selectedfrom the group consisting of water, methanol, ethanol, and ethyleneglycol at a temperature lower than a boiling point of the decomposingsolution after being cured.

A fourth molding compound of the present invention includes as a binderan aliphatic polyester, and a phenol resin or an epoxy resin, whereinthe thermosetting composition is capable of being readily decomposed ina decomposing solution containing a base and at least one solventselected from the group consisting of water, methanol, ethanol, andethylene glycol at a temperature lower than a boiling point of thedecomposing solution after being cured.

In a preferred embodiment, the addition polymerizable monomer containedin the thermosetting composition of the above-mentioned second and thirdmolding compounds is styrene.

In a preferred embodiment, the aliphatic polyester contained in thethermosetting composition of the above-mentioned first, second, andfourth molding compounds is at least one aliphatic polyester selectedfrom the group consisting of polycaprolactone, polypropiolactone,polyglycolic acid, polylactic acid, polyethylene adipate, polybutyleneadipate, polytetramethylene adipate, polyethylene succinate,polybutylene succinate, polycaprolactonediol, polycaprolactonetriol, andpoly(3-hydroxyalcanoate); and the thermosetting composition of the thirdmolding compound further contains such aliphatic polyesters other thanpolycaprolactone.

A first molded structure of the present invention includes a moldedportion made of a molding compound, integrally molded containing atleast metals, wherein at least part of the molding compound includes asa binder a thermosetting composition containing a thermosetting resinand an aliphatic polyester, decomposition of the thermosettingcomposition is promoted by decomposition of the aliphatic polyester in adecomposing solution containing at least a base after the thermosettingcomposition is cured, and the metals and the molding compound arecapable of being readily separated.

A second molded structure of the present invention includes a moldedportion made of a molding compound, integrally molded containing atleast metals, wherein at least part of the molding compound includes asa binder a thermosetting composition containing an unsaturatedpolyester, an addition polymerizable monomer, a low shrink agent otherthan an aliphatic polyester, and an aliphatic polyester, thethermosetting composition is readily decomposed in a decomposingsolution containing a base and at least one solvent selected from thegroup consisting of water, methanol, ethanol, and ethylene glycol at atemperature lower than a boiling point of the decomposing solution afterbeing cured, and the metals and the molding compound are capable ofbeing readily separated.

A third molded structure of the present invention includes a moldedportion made of a molding compound, integrally molded containing atleast metals, wherein at least part of the molding compound includes asa binder an unsaturated polyester, an addition polymerizable monomer,and polycaprolactone, the thermosetting composition is capable beingreadily decomposed in a decomposing solution containing a base and atleast one solvent selected from the group consisting of water, methanol,ethanol, and ethylene glycol at a temperature lower than a boiling pointof the decomposing solution after being cured, and the metals and themolding compound are capable of being readily separated.

A fourth molded structure of the present invention includes a moldedportion made of a molding compound, integrally molded containing atleast metals, wherein at least part of the molding compound includes asa binder a thermosetting composition containing an aliphatic polyester,and a phenol resin or an epoxy resin, the thermosetting composition iscapable being readily decomposed in a decomposing solution containing abase and at least one solvent selected from the group consisting ofwater, methanol, ethanol, and ethylene glycol at a temperature lowerthan a boiling point of the decomposing solution after being cured, andthe metals and the molding compound are capable of being readilyseparated.

In a preferred embodiment, the aliphatic polyester contained in thethermosetting composition of the above-mentioned first, second, andfourth molded structures is at least one aliphatic polyester selectedfrom the group consisting of polycaprolactone, polypropiolactone,polyglycolic acid, polylactic acid, polyethylene adipate, polybutyleneadipate, polytetramethylene adipate, polyethylene succinate,polybutylene succinate, polycaprolactonediol, polycaprolactonetriol, andpoly(3-hydroxyalcanoate), and the thermosetting composition of the thirdmolded structure further contains such aliphatic polyesters other thanpolycaprolactone.

In a preferred embodiment, at least part of the above-mentionedaliphatic polyester is dispersed in the molded portion as a filler infiber form, needle form, or particle form.

The fifth molded structure of the present invention includes a moldedportion made of a molding compound, integrally molded containing atleast metals, wherein the molded portion includes an inner moldedportion covering the metals and an outer molded portion which isprovided outside the inner molded portion and whose outermost portiondefines an outermost portion of the molded structure, and the innermolded portion contains an aliphatic polyester as a main component.

In a preferred embodiment, the above-mentioned outer molded portioncontains each of the above-mentioned thermosetting compositions as amain component.

In a preferred embodiment, the above-mentioned metals are coils and theabove-mentioned molded structure are used for a motor.

In a preferred embodiment, the above-mentioned molded structure includesa molded portion made of a molding compound, integrally moldedcontaining the coil, an insulator, and an iron core, wherein a part ofthe insulator penetrates the molded portion to be exposed to a surfaceof the molded portion.

In a preferred embodiment, the above-mentioned insulator is made of analiphatic polyester.

A sixth molded structure of the present invention includes a moldedportion made of a molding compound, integrally molded containing atleast metals, wherein at least part of the molding compound contains asa binder a thermosetting composition containing an unsaturatedpolyester, styrene, polycaprolactone, and an aliphatic polyester, thealiphatic polyester is at least one selected from the group consistingof polypropiolactone, polyglycolic acid, polylactic acid, polyethyleneadipate, polybutylene adipate, polytetramethylene adipate, polyethylenesuccinate, polybutylene succinate, polycaprolactonediol,polycaprolactonetriol, and poly(3-hydroxyalcanoate), the thermosettingcomposition is capable of being readily decomposed in a decomposingsolution containing a base and at least one solvent selected from thegroup consisting of water, methanol, ethanol, and ethylene glycol at atemperature lower than a boiling point of the decomposing solution afterbeing cured, and the metals and the molding compound are capable ofbeing readily separated.

A method for decomposing a thermosetting composition of the presentinvention includes the step of soaking the thermosetting composition ina decomposing solution containing a base and at least one solventselected from the group consisting of water, methanol, ethanol, andethylene glycol, wherein the thermosetting composition contains at leastan aliphatic polyester and a thermosetting resin.

A method for decomposing a molding compound containing as a binder athermosetting composition of the present invention includes the step ofsoaking the molding compound in a decomposing solution containing a baseand at least one solvent selected from the group consisting of water,methanol, ethanol, and ethylene glycol, wherein the thermosettingcomposition contains at least an aliphatic polyester and a thermosettingresin.

A first method for decomposing a molded structure of the presentinvention includes the step of soaking the molded structure in adecomposing solution containing a base and at least one solvent selectedfrom the group consisting of water, methanol, ethanol, and ethyleneglycol, wherein the molded structure includes a molded portion made of amolding compound, integrally molded containing at least metals, and atleast part of the molding compound includes as a binder a thermosettingcomposition containing at least an aliphatic polyester and athermosetting resin.

A second method for decomposing a molded structure of the presentinvention is a method for decomposing a molded structure including amolded portion made of a molding compound, integrally molded containingat least metals, the molded portion including an inner molded portioncovering the metals and an outer molded portion which is providedoutside the inner molded portion and whose outermost portion defines anoutermost portion of the molded structure, the inner molded portioncontaining an aliphatic polyester as a main component, the methodincluding the steps of: exposing at least part of the inner moldedportion by cutting or opening; and soaking the molded structure in agood solvent with respect to the aliphatic polyester or in a decomposingsolution containing a base and at least one solvent selected from thegroup consisting of water, methanol, ethanol, and ethylene glycol.

In a preferred embodiment, the above-mentioned decomposing solutionfurther contains at least one solvent selected from the group consistingof acetone, 2butanone, dimethylformamide, dimethyl sulfoxide, dioxane,tetrahydrofuran, diethyl ether, diethylene glycol, diethylene glycolmonoester, diethylene glycol diester, dicarboxylic acid diester, methylacetate, ethyl acetate, benzene, toluene, and phenol.

In a preferred embodiment, according to a method for decomposing athermosetting composition, a molding compound, and a molded structure ofthe present invention, the above-mentioned thermosetting composition,molding compound, or molded structure is soaked in the above-mentioneddecomposing solution at a temperature lower then a boiling point of thedecomposing solution.

A method for recycling a molded structure of the present invention is amethod for recycling a molded structure including a molded portion madeof a molding compound, integrally molded containing at least metals,wherein at least part of the molding compound contains as a binder athermosetting composition containing at least an aliphatic polyester anda thermosetting resin, the method including the steps of: soaking themolded structure in a decomposing solution containing a base and atleast one solvent selected from the group consisting of water, methanol,ethanol, and ethylene glycol so as to chemically decompose the moldedportion to a degree that a form of the molded portion cannot bemaintained; and separating the metals from the decomposed molded portionand recovering the metals.

In a preferred embodiment, the above-mentioned molded structure issoaked in the above-mentioned decomposing solution at a temperaturelower than a boiling point of the decomposing solution.

In a preferred embodiment, the above-mentioned metals are coils, and theabove-mentioned structure is a motor.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a cross-sectional view showing an embodiment of a molded motorwhich is an example of a molded structure of the present invention.

FIG. 2 is an enlarged partial cross-sectional view showing anotherembodiment of a molded motor which is an example of a molded structureof the present invention.

FIG. 3 is an enlarged partial cross-sectional view showing anotherembodiment of the molded motor shown in FIG. 2.

FIG. 4 is an enlarged partial cross-sectional view showing anotherembodiment of a molded motor which is an example of a molded structureof the present invention.

FIG. 5 is a partial cross-sectional view showing another embodiment ofthe molded motor shown in FIG. 4.

FIG. 6 is an enlarged partial cross-sectional view showing anotherembodiment of a molded motor which is an example of a molded structureof the present invention.

FIG. 7 is a perspective view showing an external appearance of aconventional molded motor.

FIG. 8 is a perspective view showing an external appearance of a statorportion of the conventional molded motor.

BEST MODE FOR CARRYING OUT THE INVENTION

In the present specification, "a thermosetting composition contains analiphatic polyester" refers to: (1) a thermosetting composition containsan aliphatic polyester as one component; and (2) a thermosettingcomposition contains a polymer having an aliphatic polyester portion.Furthermore, addition polymerizable monomers are a component used inaddition polymerization, and include aliphatic polyesters havingaddition polymerizable groups at their molecular terminals.

The first thermosetting composition of the present invention contains athermosetting resin and an aliphatic polyester, and its decomposition ispromoted by decomposition of the aliphatic polyester in a decomposingsolution containing at least a base after being cured.

The second thermosetting composition of the present invention containsan unsaturated polyester, an addition polymerizable monomer, a lowshrink agent other than an aliphatic polyester, and an aliphaticpolyester, and is capable of being readily decomposed in a decomposingsolution containing a base, and at least one solvent selected from thegroup consisting of water, methanol, ethanol, and ethylene glycol at atemperature lower than a boiling point of the decomposing solution afterbeing cured.

The third thermosetting composition of the present invention contains anunsaturated polyester, an addition polymerizable monomer, andpolycaprolactone, and is capable of being readily decomposed in adecomposing solution containing a base, and at least one solventselected from the group consisting of water, methanol, ethanol, andethylene glycol at a temperature lower than a boiling point of thedecomposing solution after being cured.

The fourth thermosetting composition of the present invention containsan aliphatic polyester, and a phenol resin or an epoxy resin, and iscapable of being readily decomposed in a decomposing solution containinga base and at least one solvent selected from the group consisting ofwater, methanol, ethanol, and ethylene glycol at a temperature lowerthan a boiling point of the decomposing solution after being cured.

Examples of the thermosetting resin contained in the first thermosettingcomposition of the present invention include an unsaturated polyester,an epoxy resin, a phenol resin, a polyurethane resin, a melamine resin,a urea resin, and a polyimide resin. The unsaturated polyester, epoxyresin, and phenol resin also can be preferably used for the otherthermosetting compositions of the present invention described later.

These thermosetting resins have condensation bonds in their molecularbackbone. Here, the condensation bond refers to a portion formed bycondensation in a thermosetting resin molecular chain; for example, itrefers to an ester bond portion in the case of an unsaturated polyesterand a methylene group portion in the case of a phenol resin.

The unsaturated polyesters contained in the first thermosettingcomposition as well as in the second and third thermosettingcompositions of the present invention can be obtained by well-knowncondensation polymerization of unsaturated and saturated polybasic acidsand glycols. Examples of the unsaturated polybasic acid include maleicacid, fumaric acid, itaconic acid, and citraconic acid, and anhydridesthereof. Examples of the saturated polybasic acid include phthalic acid,isophthalic acid, terephthalic acid, adipic acid, sebacic acid,tetrahydrophthalic acid, methyl tetrahydrophthalic acid, endomethylenetetrahydrophthalic acid, chlorendic acid, and tetrabromophthalic acid,and anhydrides thereof. Examples of the glycol include ethylene glycol,propylene glycol, diethylene glycol, dipropylene glycol, neopentylglycol, 1,3-butanediol, 1,6-hexanediol, hydrogenated bisphenol A, abisphenol A propylene oxide compound, and dibromoneopentyl glycol.

Examples of the preferred unsaturated polyester include copolymers ofisophthalic acid, fumaric acid and neopentyl glycol as represented bythe following Formula I; copolymers of phthalic anhydride, fumaricanhydride, and propylene glycol as represented by Formula II; andcopolymers of isophthalic acid, maleic anhydride, and propylene glycolas represented by Formula III. ##STR1## where n¹ to n³ are independently1 to 30.

The mixing molar ratio between the unsaturated polybasic acid and thesaturated polybasic acid is preferably in the range of 30/70 to 70/30,and more preferably in the range of 40/60 to 60/40. In the case wherethe thermosetting composition contains the unsaturated polybasic acidand the saturated polybasic acid in these ranges, it has outstandingmechanical strength and decomposing property after being cured. This isbecause an ester bond of the saturated polybasic acid is readilydecomposed in a decomposing solution and an unsaturated bond(crosslinking junctions) contributing to mechanical strength of thecured composition are present in a preferred ratio.

For practical use, the above-mentioned unsaturated polyesters areprovided as solution products in which the unsaturated polyesters aredissolved in polymerizable monomers and are called unsaturated polyesterresins.

Examples of the addition polymerizable monomer used in the presentinvention include styrene, vinyl toluene, a-methylstyrene, methylmethacrylate, vinyl acetate, diallyl phthalate, diallyl isophthalate,diallyl tetrabromophthalate, phenoxyethyl acrylate, 2-hydroxyethylacrylate, and 1,6-hexanediol diacrylate. Furthermore, aliphaticpolyesters having an addition polymerizable terminal can be used as theaddition polymerizable monomer. Considering a curing property, easinessof viscosity control, cost, and the like, styrene is preferred.

The above-mentioned addition polymerizable monomer is contained in thethermosetting composition preferably in an amount of about 25 to about150 parts by weight based on 100 parts by weight of the above-mentionedunsaturated polyester, more preferably in an amount of about 30 to about120 parts by weight, and most preferably in an amount of about 40 toabout 100. When the content of the addition polymerizable monomer isless than about 25 parts by weight, the resulting first and secondthermosetting compositions are not provided with sufficient curingproperty; thus, the mechanical strength of the cured compositionsdecreases. When the content of the addition polymerizable monomer ismore than about 150 parts by weight, a decomposing solution cannotsufficiently permeate the cured compositions; thus, the curedcompositions are not readily decomposed. When the addition polymerizablemonomer is contained in the thermosetting composition in an amount ofthe above range, the shrinkage of the composition during curing can beminimized.

Furthermore, in the preferred embodiment of the present invention, asthe addition polymerizable monomer, aliphatic polyesters having anaddition polymerizable terminal can be used. In the case where analiphatic polyester portion of the addition polymerizable monomer is thesame kind as that of aliphatic polyesters of the thermosettingcompositions, the compatibility between the addition polymerizablemonomer and the low shrink agent is very satisfactory, resulting thatuncured compositions have outstanding stability in a liquid state.Furthermore, in the case where the aliphatic polyester having anaddition polymerizable terminal is used as the addition polymerizablemonomer, the content and curing conditions of the composition can bevaried depending upon the molecular weight of the aliphatic polyester.

Examples of the low shrink agent used in the present invention includethermoplastic resins such as polyethylene, polypropylene, polystyrene,polyvinylacetate, polymethylmethacrylate, poly(ethylene vinylalcohol),acrylic copolymers, methacrylic copolymers, a styrene-butadiene blockcopolymer, and an acrylonitrile-butadiene-styrene copolymer.

The low shrink agent is contained in the thermosetting compositionpreferably in an amount of about 1 to about 100 parts by weight based on100 parts by weight of the above-mentioned unsaturated polyester, morepreferably in an amount of about 1 to about 50 parts by weight, and mostpreferably in an amount of about 1 to about 20 parts by weight. When thecontent of the low shrink agent is less than about 1 part by weight, thelow shrinking property, i.e., moldability of the composition decreases.When the content of the low shrink agent is more than about 100 parts byweight, the mechanical strength of the composition decreases.

The aliphatic polyesters used in the present invention are thermoplasticsaturated polyesters. Such polyesters are very easily decomposed in thedecomposing solution described later. Examples of the aliphaticpolyester include polymers obtained by ring-opening polymerization oflactones such as polycaprolactone represented by Formula IV andpolypropiolactone; polymers of hydroxy acids such as polylactic acidrepresented by Formula V and polyglycolic acid represented by FormulaVI; copolymers of glycols and aliphatic dicarboxylic acids representedby Formula VII such as polyethylene adipate, polytetramethylene adipate,polyethylene succinate, and polybutylene succinate; polymers having atleast one functional group at their molecular terminals such aspolycaprolactonediol represented by Formula VIII andpolycaprolactonetriol represented by Formula IX; polycaprolactone havinga terminal acrylate portion represented by Formula X; andpoly(3-hydroxyalcanoate) obtained by fermentation of microorganisms,such as poly(3-hydroxypropionate), poly(3-hydroxybutylate),poly(3-hydroxyvalerate), and poly(3-hydroxyoctanoate). Consideringstability of the thermosetting composition in a liquid state,dispersibility, and decomposing ability of the cured composition in adecomposing solution, polycaprolactone, polycaprolactonediol,polycaprolactonetriol, and polylactic acid are preferred. ##STR2## wheren⁴ to n¹⁰, Q¹ to Q², and m¹ to m³ are independently 10 to 2,000; and R¹and R² are independently hydrocarbon groups having carbon atoms of 1 to20.

In the case of the thermosetting composition containing theabove-mentioned thermosetting resin and the above-mentioned aliphaticpolyester, the aliphatic polyester is contained in the thermosettingcompositions preferably in an amount of about 1 to about 100 parts byweight based on 100 parts by weight of the thermosetting resin, morepreferably in an amount of about 2 to about 50 parts by weight, and mostpreferably in an amount of about 3 to about 20 parts by weight. When thecontent of the aliphatic polyester is less than about 1 part by weight,the resulting compositions are not sufficiently decomposed in adecomposing solution. When the content of the aliphatic polyester ismore than about 100 parts by weight, the mechanical strength of thecured compositions decreases.

In the case of the thermosetting composition containing theabove-mentioned unsaturated polyester and the above-mentioned aliphaticpolyester, the aliphatic polyester is contained in the thermosettingcomposition preferably in an amount of 1 to 100 parts by weight based on100 parts by weight of the unsaturated polyester, more preferably in anamount of 2 to 50 parts by weight, and most preferably in an amount of 3to 20 parts by weight. When the content is less than 1 part by weight,the resulting compositions are not sufficiently decomposed in adecomposing solution. When the content is more than 100 parts by weight,the mechanical strength of the cured composition decreases.

Furthermore, as described later, in the case where a filler is added tothe thermosetting composition to prepare a molding compound, theabove-mentioned aliphatic polyester is preferably contained in aslightly greater amount than the case where the filler is not added.This is because the aliphatic polyester can be sufficiently dispersed inan increased space caused by the addition of the filler. For example, athermosetting composition prepared by adding 5 parts by weight of thealiphatic polyester to 100 parts by weight of a mixture containing thealiphatic polyester and the addition polymerizable monomer will bedescribed. In the case where 150 parts by weight of calcium carbonateare added to the thermosetting composition to prepare a moldingcompound, the aliphatic polyester is added in an amount of 7.7 parts byweight instead of 5 parts by weight based on 100 parts by weight of themixture. The reason for this is that calcium carbonate has a specificgravity of 2.7, which increases the volume of the molding compound byabout 55.6 volume parts (= 150/2.7). Thus, in order for the aliphaticpolyester to disperse in the molding compound in the same way as in thecase before the increase in volume of the molding compound, another 2.7parts by weight (5*55.6/100) of the aliphatic polyester should be added.

The phenol resin used in the present invention can be obtained bypolymerizing phenols with formaldehyde by a known method. The phenolresins are classified into novolak resins obtained in the presence of anacidic catalyst and resol resins obtained in the presence of an alkalicatalyst. The novolak resins are cured by being heated with a curingagent, and the resol resins are cured merely by being heated. In thepresent invention, the novolak resins are preferred. Furthermore, in thepresent invention, phenol resins having an aliphatic polyester portionat a side chain are also preferably used.

In the case of the thermosetting composition containing theabove-mentioned phenol resin and the above-mentioned aliphaticpolyester, the aliphatic polyester is contained in the compositionpreferably in an amount of 1 to 100 parts by weight based on 100 partsby weight of the phenol resin, more preferably in an amount of 1 to 50parts by weight, and most preferably in an amount of 1 to 20 parts byweight. When the content of the aliphatic polyester is less than 1 partby weight, the resulting composition is not sufficiently decomposed in adecomposing solution. When the content of the aliphatic polyester ismore than 100 parts by weight, the mechanical strength of the curedcomposition decreases.

Examples of the epoxy resin used in the present invention includeglycidyl ether type resins, glycidyl ester type resins, glycidyl aminetype resins, epoxynovolak resins, alicyclic epoxy resins, brominatedepoxy resins, and aliphatic epoxy resins. Glycidyl ether type resinsobtained from bisphenol A and epichlorohydrin are preferably used.Furthermore, in the present invention, epoxy resins having an aliphaticpolyester portion at a side chain represented by Formula XI arepreferably used. ##STR3## where n¹¹ to n¹² are independently 1 to 30.

In the case of the thermosetting composition containing theabove-mentioned epoxy resin and the abovementioned aliphatic polyester,the aliphatic polyester is contained in the thermosetting compositionpreferably in an amount of about 1 to about 100 parts by weight based on100 parts by weight of the epoxy resin, more preferably in an amount ofabout 1 to about 50 parts by weight, and most preferably in an amount ofabout 1 to about 20 parts by weight. When the content of the aliphaticpolyester is less than about 1 part by weight, the resulting compositionis not sufficiently decomposed in a decomposing solution. When thecontent of the aliphatic polyester is more than about 100 parts byweight, the mechanical strength of the cured composition decreases.

The thermosetting compositions of the present invention preferablycontain a curing agent.

Examples of the curing agent of the above-mentioned unsaturatedpolyester include benzoyl peroxide, t-butyl perbenzoate, t-butylperoxybenzoate, t-butyl peroxylaurate, t-butyl peroxy-2-ethylhexanoate,and t-butyl peroctoate.

The curing agent is contained in the thermosetting compositionpreferably in an amount of about 0.1 to about 5 parts by weight based on100 parts by weight in total of the unsaturated polyester and theaddition polymerizable monomer, more preferably in an amount of about0.3 to about 4 parts by weight, and most preferably in an amount ofabout 0.5 to about 3 parts by weight. When the content is less than 0.1parts by weight, the composition is not sufficiently cured. When thecontent is more than about 5 parts by weight, since the amount of thecuring agent present in the three-dimensional network structure in thecured thermosetting composition is too much, the mechanical strength ofthe cured thermosetting composition becomes insufficient.

Examples of the curing agent of the phenol resins and the epoxy resinsinclude benzylmethylamine, hexamethylenetetramine,methaphenylenediamine, diaminodiphenylmethane, anddiaminodiphenylsulfone.

In the case where a novolak resin is used as the above-mentioned phenolresin, the above-mentioned curing agent can be contained in thethermosetting composition preferably in an amount of about 5 to about100 parts by weight based on 100 parts by weight of novolak resin, morepreferably in an amount of about 5 to about 40 parts by weight, and mostpreferably in an amount of about 7 to about 20 parts by weight. Thesepreferred contents of the curing agent can be applied in almost the sameway in the case where the epoxy resin is used.

Decomposition of the thermosetting composition of the present inventionis promoted when the aliphatic polyester is decomposed in a decomposingsolution containing at least a base.

Preferably, the thermosetting composition of the present invention hassolubility; that is, it can be readily decomposed in a decomposingsolution containing a base and at least one solvent selected from thegroup consisting of water, methanol, ethanol, and ethylene glycol at atemperature lower than a boiling point of the decomposing solution. Thedecomposition of the thermosetting composition in the decomposingsolution is effected as follows: Hydroxyl ions generated by the base inthe solution work as a catalyst to hydrolyze ester bonds of thealiphatic polyester in the thermosetting composition and decomposecondensation bonds of the thermosetting resin.

Examples of the base contained in the decomposing solution includealkali or alkaline earth metal hydroxides such as sodium hydroxide andpotassium hydroxide; alkali or alkaline earth metal oxides such assodium oxide and calcium oxide; and alkali or alkaline earth metalalkoxides such as sodium ethoxide and potassium t-butoxide. These basescan be used singly or in combination.

The main solvent contained in the decomposing solution can be selectedfrom the group consisting of water, methanol, ethanol, and ethyleneglycol. These can be used alone or in combination.

The decomposing solution can further contain at least one auxiliarysolvent selected from the group consisting of acetone, 2-butanone,dimethylformamide, dimethyl sulfoxide, dioxane, tetrahydrofuran, diethylether, diethylene glycol, diethylene glycol monoester, diethylene glycoldiester, dicarboxylic acid diester, methyl acetate, ethyl acetate,benzene, toluene, and phenol.

The base is contained in the decomposing solution preferably in anamount of about 0.1 to about 50% by weight, more preferably in an amountof about 1 to about 30% by weight, and most preferably in an amount ofabout 2 to about 20% by weight. When the content of the base is lessthan 0.1% by weight, the catalytic effect of the solution forhydrolyzing the composition decreases. When the content of the base ismore than 50% by weight, it is difficult to prepare the decomposingsolution; furthermore, the viscosity of the solution increases, so thatthe permeability of the solution with respect to the cured compositiondecreases, resulting in the decrease in decomposing ability.

The main solvent is contained in the entire solvent preferably in anamount of about 5 to about 100% by weight, more preferably in an amountof about 30 to about 90% by weight, and most preferably in an amount ofabout 50 to about 80% by weight. By containing the main solvent and theauxiliary solvent in these ranges, the decomposing solution hasoutstanding compatibility with the aliphatic polyester contained in thecomposition, i.e., permeability with respect to the cured composition ofthe decomposing solution and outstanding hydroxyl ions generatingability of the decomposing solution, i.e., ability to decompose esterbonds of the aliphatic polyester at room temperature or at a temperatureequal to or lower than a boiling point of the decomposing solution.Consequently, the decomposing solution has outstanding ability todecompose the thermosetting composition.

The thermosetting composition of the present invention can be in curedor uncured form. More specifically, the thermosetting composition canassume various forms such as a layered body, a coating, a putty, and anadhesive, as well as cured moldings such as those obtained by injectionmolding and transfer molding. The composition in any of these forms canbe decomposed in the decomposing solution.

Furthermore, moldings using the thermosetting composition of the presentinvention can be used at high humidities. That is, the cured compositiondoes not have its three-dimensional structure decomposed easily withwater only. Hence, it follows that the cured composition retainsoutstanding characteristics, e.g., mechanical strength even at highhumidities.

The molding compound of the present invention contains the thermosettingcomposition of the present invention at least as a binder. If required,a filler, a thickener, a mold release agent, a wax, and a colorant canbe added to the molding compound.

Examples of the filler include carbonates such as calcium carbonate andmagnesium carbonate; sulfates such as calcium sulfate and bariumsulfate; sulfites such as calcium sulfite; silicates such as clay, mica,glass balloon, montmorillonite, silicic acid, kaoline, and talc; oxidessuch as silica, diatomaceous earth, iron oxide, pumice, titanium oxide,and alumina; hydroxides such as aluminum hydroxide and magnesiumhydroxide; inorganic fillers such as graphite, glass fiber, carbonfiber, and asbestos fiber; and organic fillers such as wood flour, ricehulls, cotton, paper chip, nylon fiber, polyethylene fiber, wood, pulp,and cellulose.

In the case where a light-weight molding, which requires operability, isdesired, polyethylene fiber is preferably used as the filler. Themolding compound containing polyethylene fiber as the filler is superiorto other FRPs in terms of specific strength and specific elastic modulusconsidering its lightweight.

The filler is added to the molding compound preferably in an amount ofabout 5 to about 600 parts by weight based on 100 parts by weight of thethermosetting composition, more preferably in an amount of about 20 toabout 500, and most preferably in an amount of about 40 to about 450.The molding compound is provided with improved mechanical strength bythe addition of the filler in these ranges. Furthermore, the addition ofthe filler allows the above-mentioned aliphatic polyester to besufficiently dispersed in the cured composition, so that the decomposingsolution more readily permeates the composition, resulting in moresufficient decomposition of the molding compound.

Examples of the thickener include beryllium oxide, magnesium oxide,magnesium hydroxide, calcium oxide, calcium hydroxide, zinc oxide,benzoic acid, phthalic anhydride, tetrahydrophthalic anhydride, andmaleic anhydride.

Examples of the mold release agent include stearic acid, zinc stearate,and calcium stearate.

Examples of the wax include Hoechst wax, carnauba wax, and paraffin.

Examples of the colorant include titanium white, chromium oxide, andcarbon black.

The above-mentioned molding compound can assume a bulk molding compound(BMC), a sheet molding compound (SMC), and a pellet type moldingcompound (PMC). The molding compound can be obtained by injectionmolding, transfer molding, compression molding, and the like.

Known conditions are used for molding. For example, injection molding ispreferably conducted under the conditions of a mold temperature of150°C., an injection pressure of 150 kg/cm², and a curing time of 5minutes.

Final molded products obtained from such molding compounds can be usedin various fields: e.g., construction materials such as a bathtub, atoilet, a reservoir, and a washstand; household stuff such as a chair, adesk, and furniture; construction materials such as tile, artificialmarble, and pipe; bodies or components of transportation equipment suchas a marine vessel, an automobile, a railroad, and an aircraft; housingequipment; a decorative laminated sheet; and decorations.

The molded structure of the present invention has a molded portion madeof a molding compound of the present invention, integrally moldedcontaining at least metals. Hereinafter, a preferred embodiment of amolded motor will be described as an example of the molded structure ofthe present invention with reference to the drawings.

Referring to FIG. 1, the first preferred embodiment of the molded motorwhich is an example of the molded structure of the present inventionwill be described. FIG. 1 is a cross-sectional view showing anembodiment of a molded motor which is an example of the molded structureof the present invention. The molded motor includes a motor portion 101and a molded stator 1. The molded stator 1 includes an iron core 4, aninsulator 7 covering at least a part of the iron core 4, a coil 3 aroundthe iron core 4 and the insulator 7, and a molded portion 2 made of amolding compound integrally molded with the iron core 4, the coil 3, andthe insulator 7. The outermost portion of the molded portion 2 definesthe outermost portion of the molded stator 1. The motor portion 101 isprovided at an opening of the molded portion 2, having at least a rotaryshaft 102 and a rotator 103 attached to the rotary shaft 102, and issupported by a bracket 104. The rotator 103 is supported by a bearing105 attached to an upper wall of the opening and a bearing 106 attachedto the bracket 104. End portions (not shown) of the coil 3 extend intoan upper portion of the rotary shaft 102 so as to be connected withleads. Thus, a signal can be input through the leads. The molded stator1 may be further provided with flanges 5 having a plurality ofattachment holes 6.

The molding compound forming the molded portion 2 contains theabove-mentioned thermosetting composition at least as a binder.

According to the present invention, the thickness of the thickestportion of the molded portion 2 is preferably in the range of about 0.1to about 20 mm, more preferably in the range of about 0.2 to about 10mm, and most preferably in the range of about 0.2 to about 5 mm. It isnoted that the thickness may be varied depending upon usage.

As the insulator 7, for example, thermoplastic resins such as analiphatic polyester, polyethylene terephthalate, and polyethylene can beused. The insulator 7 is required to have the ability to retain theshape of the coil 3 during molding. Therefore, it is preferred that thesoftening point or the melting point of the insulator 7 is, for example,about 100° C or more corresponding to a molding temperature so that theinsulator 7 is not softened during molding. An aliphatic polyester isparticularly preferable for the insulator 7, since it enables the coil 3to be separated from the iron core 4 while the molded stator 1 isdecomposed. An example of an aliphatic polyester having a melting pointexceeding 100° C includes a copolymer resin represented by Formula VII:##STR4##

Referring to FIG. 2, the second preferred embodiment of the molded motorwhich is an example of the molded structure of the present inventionwill be described. FIG. 2 is an enlarged partial cross-sectional view ofa molded motor in the present embodiment. Hereinafter, the one place ofthe respective reference numerals in the drawings is identical with thatof FIG. 2 and the ten place thereof is identical with the number of thecorresponding figure.

In the present embodiment, a molded portion 22 has an inner moldedportion 22a and an outer molded portion 22b. As shown in FIG. 2, themolded stator 21 includes an iron core 24, an insulator 27 covering atleast a part of the iron core 24, a coil 23 around the iron core 24 andthe insulator 27, and a molding compound forming a molded portion 22,integrally molded with the iron core 24, the coil 23, and the insulator27. The inner molded portion 22a covers at least a part of the iron core24 and the outer molded portion 22b covers the inner molded portion 22a,and the outermost portion of the outer molded portion 22b defines theoutermost portion of the molded stator 21.

The inner molded portion 22a contains an aliphatic polyester as its maincomponent. Here, the main component is intended to have the largestcontent in the molding compound, which is about 30% by weight or morebased on the total weight of the molding compound. For example, theinner molded portion 22a is made of only the above-mentioned aliphaticpolyester or the molding compound of the present invention high inaliphatic polyester content, and the outer molded portion 22b is made ofthe molding compound of the present invention low in aliphatic polyestercontent or the conventional molding compound containing no aliphaticpolyester.

The thickness of the thickest portion of the outer molded portion 22b ispreferably in the range of about 0.1 to about 20 mm, more preferably inthe range of about 0.2 to about 10 mm, and most preferably in the rangeof about 0.2 to about 5 mm. It is noted that the thickness may be varieddepending upon usage.

The thickness of the thickest portion of the inner molded portion 22a ispreferably in the range of about 0.5 to about 10 mm, more preferably inthe range of about 1 to about 7 mm, and most preferably in the range ofabout 2 to about 5 mm. It is noted that the thickness may also be varieddepending upon usage.

The molded stator of the present embodiment having the above-mentionedstructure has environmental stability superior to that of the moldedstator 1 as shown in FIG. 1. For example, in the case where the moldedstator of the present embodiment has the outer molded portion 22b madeof the molding compound low in aliphatic polyester content orthecompountional molding compound containing no aliphatic polyester, themolded stator 21 can be used even in hot and humid surroundings whichare likely to decompose aliphatic polyesters.

Furthermore, for example, in the case where the outer molded portion 22bis made of the molding compound low in aliphatic polyester content, theinner molded portion 22a can be made of only aliphatic polyester. Inthis case, the inner molded portion 22a does not remain at a time whenthe molded stator 21 is decomposed, and thus, the iron core and the coilcan be readily kept for recycling. More specifically, aliphaticpolyesters are highly dissolved in the decomposing solution used in thepresent invention and are not cross-linked, so that when the outermolded portion 22b is ready to be separated from the inner moldedportion 22a, the inner molded portion 22a is almost dissolved in thedecomposing solution. Accordingly, at a time of the completion ofdecomposing of the molded stator 21, the iron core and the coil hassubstantially been washed.

Referring to FIG. 3, another embodiment of the molded stator 21 of amolded motor shown in FIG. 2 will be described. FIG. 3 is an enlargedpartial cross-sectional view of a molded motor.

In the present embodiment, a molded portion 32 has an inner moldedportion 32a and an outer molded portion 32b, and a side face of theouter molded portion-32b is provided with notches 38. As shown in FIG.3, the molded stator 31 includes an iron core 34, an insulator 37covering at least a part of the iron core 34, a coil 33 around the ironcore 34 and the insulator 37, and a molding compound forming a moldedportion 32, integrally molded with the iron core 34, the coil 33, andthe insulator 37. The inner molded portion 32a covers at least a part ofthe iron core 34 and the outer molded portion 32b covers the innermolded portion 32a, and the outermost portion of the outer moldedportion 32b defines the outermost portion of the molded stator 31. Theside face of the outer molded portion 32b is provided with the notches38.

It is preferred that the inner molded portion 32a is made of a moldingcompound which is more readily decomposed than that of the outer moldedportion 32b.

The notches 38 can be formed by scratching the side face of the outermolded portion 32b with a saw, a chisel, etc. or by cutting the outersurface with a drill.

The notches 38 can be formed on a top face or a bottom face of the outermolded portion 32b.

The molded stator 31 having the above-mentioned structure can be morereadily decomposed in the decomposing solution, since the notches 38increase the entire surface area of the molding compound, which comeinto contact with the decomposing solution, to increase and cause theinner molded portion 32a to be readily exposed.

Referring to FIG. 4, the third preferred embodiment of the molded motorwhich is an example of the molded structure of the present inventionwill be described. FIG. 4 is an enlarged partial cross-sectional view ofa molded motor of the present embodiment.

In the present embodiment, parts of an insulator 47 are exposed to anouter surface of an outer molded portion 42b. As shown in FIG. 4, themolded stator 41 includes an iron core 44, an insulator 47 covering atleast a part of the iron core 44, a coil 43 around the iron core 44 andthe insulator 47, and a molding compound forming a molded portion 42,integrally molded with the iron core 44, the coil 43, and the insulator47. The inner molded portion 42a covers at least a part of the iron core44 and the outer molded portion 42b covers the inner molded portion 42a,and the outermost portion of the outer molded portion 42b defines theoutermost portion of the molded stator 41. The parts of the insulator 47penetrate the outer molded portion 42b to be exposed to the outersurface of the outer molded portion 42b.

In the present embodiment, the insulator 47 is preferably made of analiphatic polyester.

As described above, the molded stator 41 having the above-mentionedstructure has an exposed portion 47a of the insulator 47. Therefore, thedecomposing solution directly comes into contact with the exposedportion 47a so as to readily decompose the exposed portion 47a, theinside of the insulator 47, and the molded portion 42 in a successivemanner. This remarkably facilitates the separation of the coil 43 andthe iron core 44 from the inner molded portion 42a.

In the present embodiment, the molded portion 42 has a structure with aninner molded portion and an outer molded portion as shown in FIG. 4;alternatively, the molded portion 42 can have a single structure asshown in FIG. 1.

Referring to FIG. 5, another embodiment of the molded stator 41 of amolded motor of FIG. 4 will be described. FIG. 5 is an enlarged partialcross-sectional view of a molded stator 51 of the present embodiment.

In the present embodiment, a part of an inner molded portion 52a isexposed to an outer surface of an outer molded portion 52b. As shown inFIG. 5, the molded stator 51 includes an iron core 54, an insulator 57covering at least a part of the iron core 54, a coil 53 around the ironcore 54 and the insulator 57, and a molding compound forming a moldedportion 52, integrally molded with the iron core 54, the coil 53, andthe insulator 57. The inner molded portion 52a covers at least a part ofthe iron core 54 and the outer molded portion 52b covers at least a partof the inner molded portion 52a, and the outermost portion of the outermolded portion 52b defines the outermost portion of the molded stator51. Part of the inner molded portion 52a penetrates the outer moldedportion 52b to be exposed to the outer surface of the outer moldedportion 52b.

It is preferred that the inner molded portion 52a is made of a moldingcompound which is more readily decomposed than that of the outer moldedportion 52b. More specifically, the content of the aliphatic polyesterof the molding compound forming the inner molded portion 52a is largerthan that of the molding compound forming the outer molded portion 52b.For example, the inner molded portion 52a is made of only theabovementioned aliphatic polyester or the molding compound of thepresent invention high in aliphatic polyester content, and the outermolded portion 52b is made of the molding compound of the presentinvention low in aliphatic polyester content or the conventional moldingcompound containing no aliphatic polyester.

As described above, in the same way as the case shown in FIG. 4, theinner molded portion 52a capable of being readily decomposed ispartially exposed to the outer surface of the outer molded portion 52a.Therefore, the decomposing solution directly comes into contact with theinner molded portion 52a so as to decompose the exposed portion of theinner molded portion 52a and the inside thereof in a successive manner.This remarkably facilitates the separation of the coil 53 and the ironcore 54 from the inner molded portion 52a.

Referring to FIG. 6, the fourth preferred embodiment of the molded motorwhich is an example of the molded structure of the present inventionwill be described. FIG. 6 is an enlarged partial cross-sectional view ofa molded motor of the present embodiment.

In the present embodiment, a molding compound forming a molded portion62 contains an aliphatic polyester as a filler 69. As shown in FIG. 6,the molded stator 61 includes an iron core 64, an insulator 67 coveringat least a part of the iron core 64, a coil 63 around the iron core 64and the insulator 67 and a molding compound forming a molded portion 62,integrally molded with the iron core 64, the coil 63, and the insulator67. The outermost portion of the molded portion 62 defines the outermostportion of the molded stator 61. The filler 69 is dispersed in themolded portion 62.

It is preferred that the aliphatic polyester used as the filler 69 haslow solubility with respect to each component of the molding compound.The filler 69 may be either in needle form, fiber form, or particleform.

In the molded stator 61 having the above-mentioned structure, the fillerportion made of an aliphatic polyester in the molded portion 62 ispreferentially decomposed while the molded stator 61 is decomposed inthe decomposing solution; as a result, a number of voids are formed inthe molded portion 62. This causes the mechanical strength of the moldedportion 62 to sufficiently decrease and facilitates the occurrence ofcracks from the voids in the molded portion 62. Thus, the coil 63 andthe iron core 64 are remarkably readily separated from the moldedportion 62 by impact or the like.

The molded motor which is an example of the molded structure of thepresent invention can be applied to a brushless DC motor, an AC motor, alinear motor, and the like.

The molded motor which is an example of the molded structure of thepresent invention can be readily decomposed by appropriately combiningthe structures of the above-mentioned preferred embodiments.

The same effect can be obtained from the molded structures other thanthe molded motor by appropriately combining the structures of thepreferred embodiments of the above-mentioned molded motors.

A method for decomposing a thermosetting composition, a moldingcompound, and a molded structure for disposal according to the presentinvention includes the step of soaking them in a decomposing solutioncontaining a base and at least one solvent selected from the groupconsisting of water, methanol, ethanol, and ethylene glycol.

A soaking time can vary depending upon a temperature of the soakingsolution. For example, when the thermosetting composition, the moldingcompound, or the molded structure are soaked in a decomposing solutionat 60° C, the time required for decomposing it can be shortened to about1/6 of the case where either one of them is soaked in a decomposingsolution at room temperature. It is noted that the temperature of thedecomposing solution is desirably less than a boiling point of theabovementioned solvent in order to prevent the solvent from evaporating.

Another method for decomposing a molded structure for disposal accordingto the present invention includes the steps of: exposing at least partof an inner molded portion by cutting or opening; and soaking the moldedstructure in a good solvent with respect to an aliphatic polyester or ina decomposing solution containing a base and at least one solventselected from the group consisting of water, methanol, ethanol, andethylene glycol.

The above-mentioned exposed portion of the inner molded portion can beformed by scratching the outer surface of the outer molded portion witha saw, a chisel, etc. or by cutting the outer surface with a drill.

Examples of the good solvent for the aliphatic polyester used in theabove-mentioned method include aromatic hydrocarbons such as toluene andxylene; ketones such as methyl ethyl ketone and acetone; esters such asethyl acetate and butyl acetate; and trichlene.

In the case where the good solvent is used, the soaking time can varydepending upon temperature and kinds of solvents. For example, in thecase where the molded stator is soaked in toluene at room temperature,the aliphatic polyester contained therein can be almost decomposed in 24hours.

Aliphatic polyesters are generally biodegradable. Thus, in the casewhere the inner molded portion made of an aliphatic polyester isexposed, the inner molded portion can be decomposed by being soaked inan aqueous solution containing lipase, which decomposes aliphaticpolyesters, soil, or sea water. It should be noted that it takes a verylong period of time to decompose the inner molded portion in thesesolutions.

The first thermosetting composition of the present invention contains athermosetting resin and an aliphatic polyester, as described above.After the thermosetting composition is cured, the aliphatic polyester isdispersed in a three-dimensional network structure of the curedcomposition. Ester bonds of the aliphatic polyester are much morereadily decomposed by a base, compared with condensation bonds of thethermosetting resin. That is, the presence of the aliphatic polyesterfacilitates the decomposing solution to permeate into the entirethree-dimensional network structure of the cured composition and thepermeated decomposing solution decomposes the aliphatic polyester,whereby permeation of the decomposing solution is further promoted. As aresult, chances of reaction between the condensation bonds of thethermosetting resin and the decomposing solution increase, wherebydecomposition of the thermosetting composition is promoted.

The second thermosetting composition of the present invention containsan unsaturated polyester, an addition polymerizable monomer, a lowshrink agent other than an aliphatic polyester, and an aliphaticpolyester. After the thermosetting composition is cured, the aliphaticpolyester is dispersed in the three-network structure of the curedcomposition. Thus, the cured thermosetting composition of the presentinvention has solubility such as being readily decomposed in adecomposing solution containing a base and at least one solvent selectedfrom the group consisting of water, methanol, ethanol, and ethyleneglycol. The reasons are as follows.

The above-mentioned aliphatic polyester has outstanding solubility withrespect to the above-mentioned decomposing solution. Thus, attractiveinteraction is caused between the decomposing solution and the aliphaticpolyester in the three-dimensional network structure. As describedabove, since the aliphatic polyester is dispersed in thethree-dimensional network structure, the decomposing solution readilypermeates into the entire three-dimensional network structure of thecured composition. The decomposing solution thus permeated decomposesester bonds in the aliphatic polyester and the unsaturated polyester bythe function of the base. Thus, the three-dimensional network structureof the cured composition can be rapidly decomposed at a temperatureequal to or lower than a boiling point of the decomposing solution to adegree that a form of the cured composition cannot be maintained.

Furthermore, the cured thermosetting compositions of the presentinvention have the same moldability and mechanical strength as those ofconventional thermosetting compositions.

In the above-mentioned thermosetting composition, in the case where theaddition polymerizable monomer is an aliphatic polyester having anaddition polymerizable terminal, the aliphatic polyester portion of theaddition polymerizable monomer forms a part of the threedimensionalnetwork structure of the cured composition and the above-mentionedaliphatic polyester is uniformly dispersed in the three-dimensionalnetwork structure. Thus, the combined effects of the aliphatic polyestermoiety of the addition polymerizable monomer and the aliphatic polyesterof the composition accelerates the decomposition of the above-mentionedmechanism. Therefore, decomposition of the cured composition is morereadily effected. Furthermore, since the addition polymerizable monomerand the aliphatic polyester have outstanding compatibility therebetween,the resulting thermosetting composition has outstanding stability in aliquid state.

Furthermore, by allowing at least one auxiliary solvent selected fromthe group consisting of acetone, 2-butanone, dimethylformamide, dimethylsulfoxide, dioxane, tetrahydrofuran, diethyl ether, diethylene glycol,diethylene glycol monoester, diethylene glycol diester, dicarboxylicacid diester, methyl acetate, ethyl acetate, benzene, toluene, andphenol to be contained indecompdecomposing solution, the permeability ofthe decomposing solution with respect to the cured composition and thesolubility of the decomposition product of the cured composition withrespect to the decomposing solution increase. As a result, decompositionof the cured substance is more promoted.

The third thermosetting composition of the present invention contains anunsaturated polyester, an addition polymerizable monomer,polycaprolatone, and preferably an aliphatic polyester. In thethermosetting composition, polycaprolactone also functions as a lowshrink agent. Furthermore, since polycaprolactone is an aliphaticpolyester, it has outstanding compatibility with aliphatic polyestersother than polycaprolactone. Thus, the use of polycaprolactone as acomponent of the thermosetting composition facilitates the preparationof the composition. In addition, the resulting thermosetting compositionhas outstanding stability in a liquid state.

This thermosetting composition has more outstanding solubility in adecomposing solution since polycaprolactone contained therein is a kindof aliphatic polyester. Furthermore, polycaprolactone allows thethermosetting composition to retain outstanding moldability and superiormechanical strength after being cured.

The fourth thermosetting composition of the present invention containsan aliphatic polyester, and a phenol resin or an epoxy resin. In thisthermosetting composition, because of the effect of the aliphaticpolyester, the three-dimensional network structure of the phenol resinor the epoxy resin after the composition is cured is readily decomposedby the same mechanism as the above.

The molding compound of the present invention contains theabove-mentioned thermosetting composition as a binder. The aliphaticpolyester contained in the binder functions so as to facilitate thedecomposition of the three-dimensional network structure of thecomposition in the same mechanism as that described above. Thus, themolding compound of the present invention can be readily decomposed in adecomposing solution containing a base and at least one solvent selectedfrom the group consisting of water, methanol, ethanol, and ethyleneglycol.

The molded structure of the present invention has a molded portion madeof the above-mentioned molding compound, so that the aliphatic polyestercontained in the binder of the molding compound functions so as tofacilitate the decomposition of the three-dimensional network structureof the binder in the same mechanism as that described above. Thus, themolded structure of the present invention is readily decomposed in adecomposing solution containing a base and at least one solvent selectedfrom the group consisting of water, methanol, ethanol, and ethyleneglycol. As a result, metals are readily separated from the moldedportion. This is remarkably effective in terms of recycling of expensivesubstances.

Furthermore, in the case where the molded structure of the presentinvention has a molded portion including an outer molded portion and aninner molded portion and the inner molded portion is made of a moldingcompound which is more readily decomposed than that of the outer moldedportion, the inner molded portion is decomposed in a short period oftime. Therefore, the inside of the molded structure assumes a hollowstate. This facilitates the separation of metals from the moldedstructure.

As described above, the thermosetting composition of the presentinvention, the molding compound containing the composition, and themolded structure using the molding compound have outstanding solubilitywith respect to a decomposing solution containing a base and at leastone solvent selected from the group consisting of water, methanol,ethanol, and ethylene glycol. Therefore, they are readily (i.e., rapidlyat a temperature equal to or lower than a boiling point of thedecomposing solution) decomposed in the decomposing solution.Furthermore, the aliphatic polyesters do not hinder the formation of thethree-dimensional network structure of the cured composition; therefore,the resulting composition has the same outstanding moldability andmechanical strength as those of the conventional compositions.

EXAMPLE 1

First, 56 parts by weight of a copolymer (EPOLAC, produced by NipponShokubai Kagaku Kogyo Co., Ltd.) of maleic acid/phthalic acid/propyleneglycol in a molar ratio of 1/1/2 containing 30% by weight of styrene, asan unsaturated polyester; 38 parts by weight of styrene as an additionpolymerizable monomer; 5 parts by weight of polystyrene as a low shrinkagent; and 6 parts by weight of polycaprolactone having a molecularweight of 40,000 (PLACCEL, produced by Daicel Chemical Industries, Ltd.)were mixed. Then, t-butylperoxybenzoate (PERBUTYL Z, produced by NipponOil and Fats Co., Ltd.) as a curing agent was added to the mixture in anamount of one part by weight based on 100 parts by weight of the mixtureto obtain a thermosetting composition. The composition thus obtained waspoured into a box-shaped mold with a thickness of 1 mm and heated at120° C for 30 minutes, thereby allowing the composition to be cured. Thecured composition was cut into a rectangular test sample fordecomposition with a size of 10 mm × 20 mm × 1 mm.

Next, 1 g of sodium hydroxide and 30 g of ethanol were mixed to preparea decomposing solution. The above-mentioned test sample was soaked inthis solution at room temperature, and weight decrease with time wasobserved. The results are shown in Table 1.

Comparative Example 1

A test sample was prepared and a decomposition test was conducted byusing the test sample in the same way as in Example 1, except thatpolycaprolactone was not contained in the thermosetting composition. Theresults are shown in Table 1.

                  TABLE 1                                                         ______________________________________                                               Weight decrease (%) of test sample                                              50 hours 100 hours  200 hours                                                                            500 hours                                 ______________________________________                                        Example 1                                                                              17       20         23     24                                        Comparative                                                                             0        0          1      1                                        Example 1                                                                     ______________________________________                                    

As is apparent from Table 1, the weight of the test sample made from thethermosetting composition of Example 1, containing polycaprolactone, wasdecreased by 17% after a lapse of 50 hours after the test sample wassoaked in the solution, whereas the weight of the test sample made fromthe thermosetting composition of Comparative Example 1, containing nopolycaprolactone, was decreased by only 1 % even after a lapse of 500hours after the test sample was soaked in the solution. The decreasedamount of the test sample of Example 1 far exceeded the content ofpolycaprolactone, i.e., about 5.7% by weight, revealing that componentsof the composition other than polycaprolactone were also decomposed in agreat amount. The NMR measurement of the resulting solution confirmedthe presence of phthalic acid contained in the unsaturated polyester. Itis understood from this fact that 50% or more of ester bonds of theunsaturated polyester as well as those of polycaprolactone were cleaved.Accordingly, the decomposition of the test sample, i.e., the curedthermosetting composition, was markedly increased because thecomposition contained polycaprolactone which was one kind of aliphaticpolyesters.

The test sample of Example 1 was visually observed after a lapse of 50hours after the test sample was soaked in the solution. This revealedthat the test sample was decomposed to many pieces without retaining theform of the original test sample.

In addition, the thermosetting composition of Example 1 had no problemsin terms of curing properties (i.e., a gelation time and a curing time),and injection molding and transfer molding properties (i.e., a spiralflow length). Furthermore, the cured composition had no problems interms of external appearance and mechanical strength.

As described above, the cured thermosetting composition of the presentinvention can be readily decomposed in the decomposing solutioncontaining a base and ethanol at room temperature while retainingoutstanding properties of the conventional thermosetting compositions.

EXAMPLE 2

First, 56 parts by weight of an unsaturated polyester (EPOLAC, producedby Nippon Shokubai Kagaku Kogyo Co., Ltd.); 38 parts by weight ofstyrene as an addition polymerizable monomer; 6 parts by weight ofpolystyrene as a low shrink agent; and 6 parts by weight ofpolycaprolactonediol having a molecular weight of 2,000 (PLACCEL 200,produced by Daicel Chemical Industries, Ltd.) as an aliphatic polyesterwere mixed. Then, t-butylperoxybenzoate (PERBUTYL Z, produced by NipponOil and Fats Co., Ltd.) as a curing agent was added to the mixture in anamount of one part by weight based on 100 parts by weight of the mixtureto obtain a thermosetting composition. The composition thus obtained waspoured into a box-shaped mold with a thickness of 1 mm and heated at120° C for 30 minutes, thereby allowing the composition to be cured. Thecured composition was cut into a rectangular test sample fordecomposition with a size of 10 mm × 20 mm × 1 mm.

Next, 1 g of sodium hydroxide as a base, 15 g of methanol, and 15 g ofwater were mixed to prepare a decomposing solution. The above-mentionedtest sample was soaked in this solution at room temperature, and weightdecrease with time was observed. The results are shown in Table 2.

EXAMPLE 3

A test sample was prepared and a decomposing test was conducted by usingthe test sample in the same way as in Example 2, except that 6 parts byweight of polylactic acid were used in place of polycaprolactonediol.The results are shown in Table 2.

EXAMPLE 4

A test sample was prepared and a decomposing test was conducted by usingthe test sample in the same way as in Example 2, except that 6 parts byweight of polycaprolactonetriol having a molecular weight of 3,000(PLACCEL 300, produced by Daicel Chemical Industries, Ltd.) was used inplace of polycaprolactonediol. The results are shown in Table 2.

EXAMPLE 5

A test sample was prepared and a decomposing test was conducted by usingthe test sample in the same way as in Example 2, except that adecomposing solution containing no methanol (i.e., a solution obtainedby mixing 1 g of sodium hydroxide and 30 g of water) was used and thetemperature of the decomposing solution was 80° C. The results are shownin Table 2.

EXAMPLE 6

A test sample was prepared in the same way as in Example 2, except thata decomposing solution containing ethylene glycol in place of water(i.e., a solution obtained by mixing 1 g of sodium hydroxide, 15 g ofmethanol, and 15 g of ethylene glycol) was used. The result is shown inTable 2.

                  TABLE 2                                                         ______________________________________                                               Weight decrease (%) of test sample                                              25 hours 50 hours   100 hours                                                                            200 hours                                 ______________________________________                                        Example 2                                                                              21       32         34     35                                        Example 3                                                                              17       24         26     27                                        Example 4                                                                               7       13         17     17                                        Example 5                                                                              19       30         33     34                                        Example 6                                                                              14       19         24     28                                        ______________________________________                                    

Notes: In Examples 2 to 4, the decomposing solutions at room temperaturecontaining methanol and water were used; in Example 5, the decomposingsolution at 80° C not containing methanol was used; in Example 6, thedecomposing solution at room temperature containing ethanol and ethyleneglycol was used.

As is apparent from Table 2, in Examples 2 to 6, the test samplestreated with the decomposing solutions containing a base and water,methanol, or ethylene glycol decreased in weight by at least 17% after alapse of 200 hours after the test samples were soaked in the solutions,showing outstanding solubility. Comparing Example 2 with Example 5, thedecomposing solution containing sodium hydroxide, and water the samedecomposing property as that of the decomposing solution containingsodium hydroxide, methanol, and water by being heated up to 80° C..Comparing Example 2 with Example 6, the decomposing solution usingmethanol and water as a solvent had outstanding decomposing ability thanthat of the decomposing solution using methanol and ethylene glycol as asolvent.

Furthermore, the test samples of Examples 2 to 6 were visually observedafter a lapse of 200 hours after the test samples were soaked in thesolution. This revealed that the test sample were in a soft rubberystate, which were capable of being readily processed, e.g., crushed ordeformed.

As described above, the cured thermosetting composition of Examples 2 to6 can be readily decomposed in the decomposing solution containing abase, water, methanol, and ethylene glycol at room temperature or at atemperature equal to or lower than a boiling point of the decomposingsolution while retaining outstanding properties of the conventionalthermosetting composition.

EXAMPLE 7

First, 56 parts by weight of an unsaturated polyester (EPOLAC, producedby Nippon Shokubai Kagaku Kogyo Co., Ltd.); 38 parts by weight ofstyrene as an addition polymerizable monomer; 6 parts by weight ofpolystyrene as a low shrink agent; and 6 parts by weight ofpolycaprolactone having a molecular weight of 40,000 (PLACCEL, producedby Daicel Chemical Industries, Ltd.) were mixed. Thent-butylperoxylaurate (PERBUTYL Z, produced by Nippon Oil and Fats Co.,Ltd.) as a curing agent was added to the mixture in an amount of onepart by weight based on 100 parts by weight of the mixture to obtain athermosetting composition. The composition thus obtained was poured intoa box-shaped mold with a thickness of 1 mm and heated at 120° C. for 30minutes, thereby allowing the composition to be cured. The curedcomposition was cut into a rectangular test sample for decompositionwith a size of 10 mm × 20 mm × 1 mm.

Next, 1 g of sodium hydroxide as a base, 27 g of methanol, and 3 g ofwater were mixed to prepare a decomposing solution. The above-mentionedtest sample was soaked in this solution at room temperature, and weightdecrease with time was observed. The results are shown in Table 3.

EXAMPLE 8

A test sample was prepared and a decomposing test was conducted by usingthe test sample in the same way as in Example 7, except that polystyreneas a low shrink agent was not used. The results are shown in Table 3.

EXAMPLE 9

A test sample was prepared and a decomposing test was conducted by usingthe test sample in the same way as in Example 7, except thatpolycaprolactonediol having a molecular weight of 2,000 (PLACCEL 200,produced by Daicel Chemical Industries, Ltd.) was used in place ofpolycaprolactone. The results are shown in Table 3.

EXAMPLE 10

A test sample was prepared and a decomposing test was conducted in thesame way as in Example 7, except that 6 parts by weight ofpolycaprolactonediol having a molecular weight of 2,000 (PLACCEL 200,produced by Daicel Chemical Industries, Ltd.) was further used andpolystyrene as a low shrink agent was not used. The results are shown inTable 3.

Comparative Example 2

A test sample was prepared and a decomposing test was conducted in thesame way as in Example 7, except that the thermosetting composition didnot contain polycaprolactone. The results are shown in Table 3.

                  TABLE 3                                                         ______________________________________                                               Weight decrease (%) of test sample                                              50 hours 100 hours  200 hours                                                                            500 hours                                 ______________________________________                                        Example 7                                                                              15       23         24     24                                        Example 8                                                                              18       27         32     33                                        Example 9                                                                              17       27         30     31                                        Example 10                                                                             20       32         37     38                                        Comparative                                                                             0        0          1      1                                        Example 2                                                                     ______________________________________                                    

As is apparent from Table 3, the weight of the test samples made fromthe thermosetting compositions of Examples 7 to 10 was decreased by atleast 24% after a lapse of 500 hours after the test samples were soakedin the solutions, whereas the weight of the test sample made from thethermosetting composition of Comparative Example 2 was decreased by only1% even after a lapse of 500 after the test sample was soaked in thesolution.

The weight of the test samples made from the thermosetting compositionsof Examples 8 and 10 containing no low shrink agent was decreased in aslightly larger proportion than that of Examples 7 and 9. The reason forthis is conspolystyas follows: As containing polystyrene as the lowshrink agents which are not hydrophilic, the cured thermosettingcompositions of Examples 7 and 9 do not allow the decomposing solutionsto permeate thereto so readily as the cured thermosetting compositionsof Examples 8 and 10.

The shrinkage of the compositions upon being cured was 0.1% or less inExamples 7 to 10, and Comparative Example 2. Thus, in the samplesobtained from the thermosetting composition of Example 10 not containinga low shrink agent, shrinkage slightly decreased. The thermosettingcomposition containing polycaprolactone exhibited the same shrinkage asthat of the composition of Comparative Example 2 containing the lowshrink agent. It is understood from this fact that polycaprolactone isan aliphatic polyester capable of working as a shrink agent.

The test samples of Examples 7 to 10 were visually observed after alapse of 500 hours after the test samples were soaked in the solution.This revealed that the test samples were in a soft rubbery state, whichwere capable of being readily processed, e.g., crushed or deformed.

In addition, the thermosetting compositions of Examples 7 to 10 had noproblems in terms of curing properties (i.e., a gelation time and acuring time), and injection molding and transfer molding properties(i.e., a spiral flow length). Furthermore, the cured compositions had noproblems in terms of external appearance and mechanical strength.

As described above, the cured thermosetting compositions of the presentinvention can be readily decomposed in the decomposing solutionscontaining a base, methanol, and water at room temperature whileretaining outstanding properties of the conventional thermosettingcompositions.

EXAMPLE 11

First, 35 parts by weight of unsaturated polyester (EPOLAC, produced byNippon Shokubai Kagaku Kogyo Co., Ltd.), 15 parts by weight of styrene,and 50 parts by weight of a hydroxyethyl acrylate monomer (produced byDaicel Chemical Industries, Ltd.) having a polycaprolactone portion at aside chain were mixed. Then, 5 parts by weight of polymethylmethacrylateas a low shrink agent, 6 parts by weight of polycaprolactone as analiphatic polyester, and 1 part by weight of t-butylperoxybenzoate(PERBUTYL Z, produced by Nippon Oil and Fats Co., Ltd.) as a curingagent were added to 100 parts by weight of the mixture to obtain athermosetting composition. The composition was poured into a box-shapedmold with a thickness of 1 mm and heated at 120° C for 30 minutes,thereby allowing the composition to be cured. The cured composition wascut into a rectangular test sample for decomposition with a size of 10mm × 20 mm × 1 mm.

Next, 1 g of sodium hydroxide and 30 g of methanol were mixed to preparea decomposing solution. The above-mentioned test sample was soaked inthis solution at room temperature, and weight decrease with time wasobserved. The results are shown in Table 4.

EXAMPLE 12

A test sample was prepared and a decomposing test was conducted in thesame way as in Example 11, except that a decomposing solution preparedby mixing 1 g of sodium hydroxide, 27 g of ethanol, and 3 g of water wasused. The results are shown in Table 4.

Comparative Example 3

A test sample was prepared and a decomposing test was conducted by usingthe test sample in the same way as in Example 11, except that adecomposing solution containing no base (i.e., a solution obtained bymixing 27 g of ethanol and 3 g of water) was used. The results are shownin Table 4.

EXAMPLE 13

First, 65 parts by weight of unsaturated polyester (EPOLAC, produced byNippon Shokubai Kagaku Kogyo Co., Ltd.), 35 parts by weight of styrene,and 15 parts by weight of ethyl acrylate were mixed. Then, 5 parts byweight of polymethylmethacrylate as a low shrink agent, 6 parts byweight of polycaprolactone, and 1 part by weight oft-butylperoxybenzoate (PERBUTYL Z, produced by Nippon Oil and Fats Co.,Ltd.) as a curing agent were added to 57.5 parts by weight of themixture to obtain a thermosetting composition. The composition waspoured into a box-shaped mold with a thickness of 1 mm and heated at120° C for 30 minutes, thereby allowing the composition to be cured. Thecured composition was cut into a rectangular test sample fordecomposition with a size of 10 mm × 20 mm × 1 mm.

Next, 1 g of sodium hydroxide and 30 g of methanol were mixed to preparea decomposing solution. The above-mentioned test sample was soaked inthis solution at room temperature, and weight decrease with time wasobserved. The results are shown in Table 4.

EXAMPLE 14

A test sample was prepared and a decomposing test was conducted by usingthe test sample in the same way as in Example 13, except that adecomposing solution prepared by mixing 1 g of sodium hydroxide, 27 g ofethanol, and 3 g of water was used. The results are shown in Table 4.

Comparative Example 4

A test sample was prepared and a decomposing test was conducted by usingthe test sample in the same way as in Example 13, except that adecomposing solution containing no base (i.e., a solution obtained bymixing 27 g of ethanol and 3 g of water) was used. The results are shownin Table 4.

                  TABLE 4                                                         ______________________________________                                               Weight decrease (%) of test sample                                              50 hours 100 hours  200 hours                                                                            500 hours                                 ______________________________________                                        Example 11                                                                             24       31         33     34                                        Example 12                                                                             22       30         40     39                                        Example 13                                                                             17       19         20     21                                        Example 14                                                                             14       21         24     25                                        Comparative                                                                             0        0          0      0                                        Example 3                                                                     Comparative                                                                             0        0          0      0                                        Example 4                                                                     ______________________________________                                    

Notes: In Examples 11 and 13, the decomposing solutions containingmethanol and sodium hydroxide were used; in Examples 12 and 14, thedecomposing solutions containing ethanol, sodium hydroxide, and waterwere used; in Comparative Examples 3 and 4, the decomposing solutionscontaining no sodium hydroxide were used.

As is apparent from Table 4, in Examples 11 to 14 and ComparativeExamples 3 and 4, the weight of the test samples of Examples 11 to 14treated with the decomposing solutions containing sodium hydroxide andethanol was decreased by at least 21% after a lapse of 500 hours afterthe test samples were soaked in the solutions, whereas the weight of thetest samples of Comparative Examples 3 and 4 treated with thedecomposing solution not containing sodium hydroxide was not decreasedeven after a lapse of 500 hours after the test samples were soaked inthe solutions. The comparisons between Examples 11 and 12 and betweenExamples 13 and 14 revealed that the cured thermosetting compositionswere more readily decomposed in the decomposing solutions containingwater in an appropriate amount. Also, the comparisons between Examples11 and 13 and between Examples 12 and 14 revealed that the thermosettingcompositions containing an aliphatic polyester having at least anaddition polymerizable group at its molecular terminals as an additionpolymerizable monomer were more readily decomposed in the decomposingsolutions.

The NMR measurement of the resulting solution confirmed the presence ofphthalic acid contained in the unsaturated polyester. It is understoodfrom this fact that ester bonds of the unsaturated polyester as well asthose of the aliphatic polyester were decomposed.

The test samples of Examples 11 to 14 were visually observed after alapse of 500 hours after the test samples were soaked in the solution.This revealed that the test samples were in a soft rubbery state, whichwere capable of being readily processed, e.g., crushed or deformed.

As described above, the cured thermosetting composition of Examples 11to 14 can be readily decomposed in the decomposing solutions containinga base and water, ethanol, or methanol at room temperature or at atemperature while retaining outstanding properties of the conventionalthermosetting compositions.

EXAMPLE 15

As a polymer having an aliphatic polyester portion at a side chain, anepoxy resin having a lactone portion at a side chain (PLACCEL G,produced by Daicel Chemical Industries, Ltd.), obtained by modifyingsecondary hydroxyl groups of a bisphenol-epichlorohydrin resin intolactone, was used. One part by weight of benzylmethylamine as a curingagent was mixed with 10 parts by weight of the resin to obtain athermosetting composition. Then, the composition thus obtained waspoured into a box-shaped mold with a thickness of 1 mm and heated at100° C for 30 minutes, thereby allowing the composition to be cured. Thecured composition was cut into a rectangular test sample fordecomposition disposal with a size of 10 mm × 20 mm × 1 mm.

The cured composition had no problem in terms of mechanical strength.

Next, 1 g of sodium hydroxide, 24 g of methanol, and 6 g of water weremixed to prepare a decomposing solution. The above-mentioned test samplewas soaked in this solution at room temperature, and weight decreaseafter a lapse of 150 hours after the test sample was soaked in thesolution was measured. The resulting weight decrease was about 22%. Atthis time, the test sample was visually observed. This revealed that thetest sample was decomposed to many pieces without retaining the form ofthe original test sample.

As described above, the cured thermosetting composition of Example 15can be readily decomposed in the decomposing solution containing a baseand methanol and water at room temperature while retaining outstandingproperties of the conventional thermosetting compositions.

EXAMPLE 16

First, 38 parts by weight of a phenol resin (STANDLITE CP, produced byHitachi Chemical Co., Ltd.; or FUDOWLITE, produced by Fudow Co., Ltd.),2 parts by weight of polycaprolactone having a molecular weight of40,000 (PLACCEL, produced by Daicel Chemical Industries, Ltd.), 50 partsby weight of calcium carbonate having a particle size of about 5 μm, and10 parts by weight of glass fibers having a diameter of about 0.5 mm anda length of 20 mm were mixed. Then, hexamethylenetetramine as a curingagent was added to the resulting mixture in an amount of 4 parts byweight based on 38 parts by weight of the phenol resin and 2 parts byweight of the polycaprolactone to obtain a thermosetting composition.The composition thus obtained was poured into a box-shaped mold with athickness of 1 mm and heated at 140° C for about 30 minutes, therebyallowing the composition to be cured. The cured composition was cut intoa rectangular test sample for decomposition with a size of 10 mm × 20 mm× 1 mm.

Next, 1 g of sodium hydroxide, 24 g of methanol, and 6 g of water weremixed to prepare a decomposing solution. The above-mentioned test samplewas soaked in this solution at room temperature, and weight decreasewith time was observed. The results are shown in Table 5.

EXAMPLE 17

First, 38 parts by weight of an epoxy resin (STANDLITE CEL, produced byHitachi Chemical Co., Ltd.; or EPICLONE, produced by Dainippon Ink andChemicals, Inc.), 2 parts by weight of polycaprolactone having amolecular weight of 40,000 (PLACCEL, produced by Daicel ChemicalIndustries, Ltd.), 50 parts by weight of calcium carbonate having aparticle size of about 5 μm, and 10 parts by weight of glass fibershaving a diameter of about 0.5 mm and a length of 20 mm were mixed.Then, hexamethylenetetramine as a curing agent was added to theresulting mixture in an amount of 4 parts by weight based on 38 parts byweight of the epoxy resin and 2 parts by weight of the polycaprolactoneto obtain a thermosetting composition. The composition thus obtained waspoured into a box-shaped mold with a thickness of 1 mm and heated at100° C for about 30 minutes, thereby allowing the composition to becured. The cured composition was cut into a rectangular test sample fordecomposition with a size of 10 mm × 20 mm × 1 mm.

Next, 1 g of sodium hydroxide, 24 g of methanol, and 6 g of water weremixed to prepare a decomposing solution. The above-mentioned test samplewas soaked in this solution at room temperature, and weight decreasewith time was observed. The results are shown in Table 5.

                  TABLE 5                                                         ______________________________________                                               Weight decrease (%) of test sample                                              50 hours 100 hours  200 hours                                                                            500 hours                                 ______________________________________                                        Example 16                                                                             2        4          8      9                                         Example 17                                                                             3        4          8      8                                         ______________________________________                                    

As is apparent from Table 5, the weight of the test samples made fromthe thermosetting compositions of Examples 16 and 17 was decreased byabout 10% after a lapse of 500 hours after the test samples were soakedin the solutions.

The test samples were visually observed. This revealed that the testsamples were in a brittle state, which were capable of being processed,e.g., crushed or deformed.

In addition, the thermosetting compositions of Examples 16 and 17 had noproblems in terms of curing properties, and injection molding andtransfer molding properties. Furthermore, the cured compositions had noproblems in terms of external appearance and mechanical strength.

As described above, the cured thermosetting compositions of Examples 16and 17 can be readily decomposed in the decomposing solutions containinga base and methanol and water at room temperature while retainingoutstanding properties of the conventional thermosetting compositions.

EXAMPLE 18

First, 24 parts by weight of an unsaturated polyester (EPOLAC, producedby Nippon Shokubai Kagaku Kogyo Co., Ltd.), 6 parts by weight of astyrene containing 30% by weight of polycaprolactone having a molecularweight of 40,000 (PLACCEL, produced by Daicel Chemical Industries,Ltd.), 4 parts by weight of polystyrene as a low shrink agent, and 0.5parts by weight of t-butylperoxybenzoate (PERBUTYL Z, produced by NipponOil and Fats Co., Ltd.) were mixed to obtain a thermosetting compositionas a binder.

Next, 57 parts by weight of calcium carbonate as a filler, 2 parts byweight of zinc stearate as a mold release agent, and 1 part by weight ofmagnesium oxide as a thickener were dry-mixed using a kneader for about5 minutes. Thirty parts by weight of the above-mentioned binder weregradually added to the resulting mixture while being kneaded to give ahomogeneous paste. Ten parts by weight of glass fibers were quicklyadded to the paste while being kneaded so as to be uniformly dispersedtherein. At the time when the glass fibers were homogeneously dispersedin the paste, kneading was stopped to provide a BMC as a moldingcompound.

The molding compound was transfer-molded at a mold temperature of 150° Cunder an injection pressure of 150 kg/cm² to give a plate-shapedmolding.

The molding thus obtained had no problems in terms of curing properties(i.e., a gelation time and a curing time) and a spiral flow length.Furthermore, the dimensional stability of the molding is superior tothat of the conventional FRPs, and the molding had no problems in termsof external appearance and mechanical strength.

Next, 2 g of sodium hydroxide, 10 g of ethanol and 20 g of methanol weremixed to prepare a decomposing solution. The above-mentioned molding wassoaked in this solution at room temperature, and its state after a lapseof 200 hours after the molding was soaked in the solution was visuallyobserved. This revealed that the molding was decomposed to many pieceswithout retaining the form of the original molding.

As described above, the molding compound of the present example can bereadily decomposed in the decomposing solution containing a base andethanol and methanol at room temperature while retaining outstandingproperties of the conventional FRPs.

EXAMPLE 19

First, 12 parts by weight of an unsaturated polyester (RIGOLAC, producedby Showa Highpolymer Co., Ltd.), 7 parts by weight of styrene, 1 part byweight of polycaprolactone having a molecular weight of 40,000 (PLACCEL,produced by Daicel Chemical Industries, Ltd.), 1 part by weight ofpolyvinyl acetate as a low shrink agent, and 0.4 parts by weight oft-butylperoxybenzoate (PERBUTYL Z, produced by Nippon Oil and Fats Co.,Ltd.) were mixed to obtain a thermosetting composition as a binder.

Next, 57 parts by weight of calcium carbonate having a particle size of4 to 6 μm as a filler, 1.2 parts by weight of zinc stearate as a moldrelease agent, and 1 part by weight of calcium hydroxide as a thickenerwere dry-mixed using a kneader. Thirty parts by weight of theabove-mentioned binder were gradually added to the resulting mixturewhile being kneaded to give a homogeneous paste. Ten parts by weight ofpolyethylene fibers were quickly added to the paste while being kneadedso as to be uniformly dispersed therein. At the time when thepolyethylene fibers were homogeneously dispersed in the paste, kneadingwas stopped to provide a BMC as a molding compound.

The molding compound was press-charged into a hopper portion of aninjection molding machine equipped with a plunger and a screw, andinjection-molded under the conditions of a mold temperature of 150° C, ascrew speed of 50 rpm, an injection pressure of 140 kg/cm², an injectiontime of 5 seconds, and a dwelling time of 30 seconds, thereby providinga cylindrical molding with a diameter of 20 mm and a height of 15 mm.

The molding was lightweight and had an outstanding fabricating property.

Next, 2 g of sodium hydroxide, 20 g of ethanol and 10 g of water weremixed to prepare a decomposing solution. The above-mentioned molding wassoaked in this solution at room temperature, and its state after a lapseof 200 hours after the molding was soaked in the solution was visuallyobserved. This revealed that the molding was in a brittle state, whichwas capable of being processed, e.g., crushed or deformed. Themechanical strength of the molding decreased to about 1/8 of that beforesoaking.

As described above, the molding of the present example had its strengthreadily degraded at room temperature by being soaked in the decomposingsolution containing a base and methanol and water.

EXAMPLE 20

First, 28 parts by weight of an unsaturated polyester (EPOLAC, producedby Nippon Shokubai Kagaku Kogyo Co., Ltd.), 2.5 parts by weight ofpolycaprolactonediol, 20 parts by weight of styrene, 2 parts by weightof polystyrene as a low shrink agent, and 0.4 parts by weight oft-butylperoxy-2-ethylhexanoate (PERBUTYL O, produced by Nippon Oil andFats Co., Ltd.) were mixed to obtain a thermosetting composition as abinder.

Next, 58 parts by weight of calcium carbonate as a filler, 1.5 parts byweight of zinc stearate as a mold release agent, and 0.5 parts by weightof magnesium oxide as a thickener were dry-mixed using a kneader. Fortyparts by weight of the above-mentioned binder were gradually added tothe resulting mixture while being kneaded to give a homogeneous paste.

Glass fibers were chopped with a cutter. The chopped strands thusobtained were sprinkled over the surface of the polyethylene film, andthe film was impregnated with the paste. The resulting film was rolledup and thickened by aging, as necessary, to provide an SMC as a moldingcompound.

The molding compound was compression-molded at a mold temperature of 65°C and a pressure of 100 kg/cm² to provide a molding.

The molding thus obtained had no problems in terms of curing properties,and a molding property. Furthermore, the molding had no problems interms of external appearance and mechanical strength.

Next, 1 g of sodium hydroxide, 25 g of methanol, and 5 g of water weremixed to prepare a decomposing solution. The above-mentioned molding wassoaked in this solution at room temperature, and its change in statewith time was observed. This revealed that the molding had its weightand strength decreased.

As described above, the molding compound of the present example can bereadily decomposed in the decomposing solution containing a base andmethanol and water at room temperature.

EXAMPLE 21

First, 52 parts by weight of an unsaturated polyester (EPOLAC, producedby Nippon Shokubai Kagaku Kogyo Co., Ltd.), 28 parts by weight ofstyrene, and a solution containing 6 parts by weight of polycaprolactonehaving a molecular weight of 40,000 (PLACCEL, produced by DaicelChemical Industries, Ltd.) and 14 parts by weight of styrene were mixed.Then, 6 parts by weight of polyvinyl acetate as a low shrink agent and 1part by weight of t-butylperoxybenzoate (PERBUTYL Z, produced by NipponOil and Fats Co., Ltd.) as a curing agent were added to the resultingmixture to obtain a thermosetting composition as a molding compound.

The molding compound was integrally molded with an iron core, a coil,and an insulator to fabricate a molded motor as shown in FIG. 1. Themolded motor was soaked in a decomposing solution containing 1.25 g ofsodium hydroxide, 24 g of ethanol, and 6 g of water for 24 hours.Thereafter, the molding compound was attempted to be separated from thecoil and the iron core. As a result, the molding compound was readilyhand-removed from the coil and the iron core.

Another 20-hour soaking made it possible to completely remove theremaining molding compound from the coil.

EXAMPLE 22

First, 52 parts by weight of an unsaturated polyester (EPOLAC, producedby Nippon Shokubai Kagaku Kogyo Co., Ltd.), 28 parts by weight ofstyrene, and a solution containing 6 parts by weight ofpolycaprolactonediol having a molecular weight of 2,000 (PLACELL 200,produced by Daicel Chemical Industries, Ltd.) and 14 parts by weight ofstyrene were mixed. Then, 6 parts by weight of polystyrene as a lowshrink agent and 1 part by weight of t-butylperoxybenzoate (PERBUTYL Z,produced by Nippon Oil and Fats Co., Ltd.) as a curing agent were addedto the resulting mixture to obtain a thermosetting composition as amolding compound.

The molding compound was integrally molded with an iron core, a coil,and an insulator to fabricate a molded motor as shown in FIG. 1. Themolded motor was soaked in a decomposing solution containing 1.25 g ofsodium hydroxide, 6 g of ethanol, and 24 g of dimethyl sulfoxide for 24hours. Thereafter, the molding compound was attempted to be separatedfrom the coil and the iron core. As a result, the molding compound wasreadily hand-removed from the coil and the iron core.

Another 20-hour soaking made it possible to completely remove theremaining molding compound from the coil.

EXAMPLE 23

First, 52 parts by weight of an unsaturated polyester (EPOLAC, producedby Nippon Shokubai Kagaku Kogyo Co., Ltd.), 42 parts by weight ofstyrene, and 6 parts by weight of polylactic acid (produced by ShimadzuCorporation) having a particle size of 250 to 500 μm were mixed. Then, 6parts by weight of polystyrene as a low shrink agent and 1 part byweight of t-butylperoxybenzoate (PERBUTYL Z, produced by Nippon Oil andFats Co., Ltd.) as a curing agent were added to the resulting mixture toobtain a thermosetting composition as a molding compound.

In the same way as in Example 21, the molding compound was integrallymolded with an iron core, a coil, and an insulator to fabricate a moldedmotor as shown in FIG. 1. The molded motor was soaked in a decomposingsolution containing 1.25 g of sodium hydroxide, 24 g of ethanol, and 6 gof water for 24 hours. Thereafter, the molding compound was attempted tobe separated from the coil and the iron core. As a result, the moldingcompound was readily hand-removed from the coil and the iron core.

Another 20-hour soaking made it possible to completely remove theremaining molding compound from the coil.

It should be noted that polylactic acid can be needle-shaped orfiber-shaped instead of being particleshaped.

EXAMPLE 24

First, 52 parts by weight of an unsaturated polyester (EPOLAC, producedby Nippon Shokubai Kagaku Kogyo Co., Ltd.), 42 parts by weight ofstyrene, 6 parts by weight of polybutylene succinate (BIONOLLE, producedby Showa Highpolymer Co., LTD.), 6 parts by weight of polypolystyrene asa low shrink agent, and 1 part by weight of t-butylperoxybenzoate(PERBUTYL Z, produced by Nippon Oil and Fats Co., Ltd.) as a curingagent were mixed to obtain a thermosetting composition as a moldingcompound.

In the same way as in Example 21, the molding compound was integrallymolded with an iron core, a coil, and an insulator to fabricate a moldedmotor as shown in FIG. 1. The molded motor was soaked in a decomposingsolution containing 1.25 g of sodium hydroxide, 24 g of ethanol, and 6 gof water for 24 hours. Thereafter, the molding compound was attempted tobe separated from the coil and the iron core. As a result, the moldingcompound was readily hand-removed from the coil and the iron core.

Another 20-hour soaking made it possible to completely remove theremaining molding compound from the coil.

EXAMPLE 25

First, 52 parts by weight of an unsaturated polyester (EPOLAC, producedby Nippon Shokubai Kagaku Kogyo Co., Ltd.), 28 parts by weight ofstyrene, and a solution containing 7 parts by weight of polycaprolactonehaving a molecular weight of 40,000 (PLACCEL, produced by DaicelChemical Industries, Ltd.) and 13 parts by weight of styrene were mixed.Then, 6 parts by weight of polystyrene as a low shrink agent and 1 partby weight of t-butylperoxybenzoate (PERBUTYL Z, produced by Nippon Oiland Fats Co., Ltd.) as a curing agent were added to the resultingmixture to obtain a thermosetting composition as a binder.

Then, 100 parts by weight of calcium bicarbonate (produced by MaruoCalcium Co., Ltd.) having an average particle size of 20 μm were addedto the binder to provide a molding compound.

In the same way as in Example 21, the molding compound was integrallymolded with an iron core, a coil, and an insulator to fabricate a moldedmotor as shown in FIG. 1. The molded motor was soaked in a decomposingsolution containing 1.25 g of sodium hydroxide, 24 g of ethanol, and 6 gof water for 24 hours. Thereafter, the molding compound was attempted tobe separated from the coil and the iron core. As a result, the moldingcompound readily fell to pieces with light taps of a hammer and wasremoved from the coil and the iron core.

Another 20-hour soaking made it possible to completely remove theremaining molding compound from the coil.

EXAMPLE 26

First, 52 parts by weight of an unsaturated polyester (EPOLAC, producedby Nippon Shokubai Kagaku Kogyo Co., Ltd.), 28 parts by weight ofstyrene, and a solution containing 8 parts by weight of polycaprolactone(PLACCEL, produced by Daicel Chemical Industries, Ltd.) having amolecular weight of 40,000 and 12 parts by weight of styrene were mixed.Then, 6 parts by weight of polystyrene as a low shrink agent and 1 partby weight of t-butylperoxybenzoate (PERBUTYL Z, produced by Nippon Oiland Fats Co., Ltd.) as a curing agent were added to the resultingmixture to obtain a thermosetting composition as a binder.

Then, 100 parts by weight of calcium bicarbonate (produced by MaruoCalcium Co., Ltd.) having an average particle size of 20 μm and glassfibers having a length of 20 mm were added to the binder to provide amolding compound.

In the same way as in Example 21, the molding compound was integrallymolded with an iron core, a coil, and an insulator to fabricate a moldedmotor as shown in FIG. 1. The molded stator was soaked in a decomposingsolution containing 1.25 g of sodium hydroxide, 24 g of ethanol, and 6 gof water for 24 hours. Thereafter, the molding compound was attempted tobe separated from the coil and the iron core. As a result, the moldingcompound readily fell to pieces with light taps of a hammer and wasremoved from the coil and the iron core.

Another 20-hour soaking made it possible to completely remove theremaining molding compound from the coil.

Comparative Example 5

First, 52 parts by weight of an unsaturated polyester (EPOLAC, producedby Nippon Shokubai Kagaku Kogyo Co., Ltd.), 42 parts by weight ofstyrene, 6 parts by weight of polystyrene as a low shrink agent, and 1part by weight of t-butylperoxybenzoate (PERBUTYL Z, produced by NipponOil and Fats Co., Ltd.) as a curing agent were mixed to obtain athermosetting composition as a molding compound.

In the same way as in Example 21, the molding compound was integrallymolded with an iron core, a coil, and an insulator to fabricate a moldedmotor as shown in FIG. 1. The molded stator was soaked in a decomposingsolution containing 1.25 g of sodium hydroxide, 24 g of ethanol, and 6 gof water for 24 hours. Thereafter, the molding compound was attempted tobe separated from the coil and the iron core; however, the moldingcompound was not readily removed from the coil and the iron core.

EXAMPLE 27

An aliphatic polyester (BIONOLLE, produced by Showa Highpolymer Co.,Ltd.) having a melting point of 114° C, represented by Formula VII, wasmolded with an iron core, a coil, and an insulator so as to cover atleast a part of the iron core. The molding thus obtained was integrallymolded with the molding compound of Example 26 to provide a molded motorhaving an inner molded portion and an outer molded portion as shown inFIG. 2. The thickest portion of the outer molded portion had a thicknessof about 6 mm. ##STR5##

The molded motor was soaked in a decomposing solution containing 1.25 gof sodium hydroxide, 24 g of ethanol, and 6 g of water for 24 hours.Thereafter, the molding compound was tried to be separated from the coiland the iron core. As a result, the outer molded portion was removedfrom the coil and the iron core with light taps of a hammer, and theinner molded portion was exposed.

Another 24-hour soaking made it possible to completely remove the innermolded portion and the insulator from the coil and the iron core.

EXAMPLE 28

The molded motor was soaked in the decomposing solution of Example 27for 24 hours in the same way as in Example 27, except that the outermolded portion was scratched with a chisel so as to partially expose theinner molded portion before soaking the molded stator. After beingsoaked, the inner molded portion and the insulator were completelydissolved in the decomposing solution, and the inside of the moldedstator became hollow. The resulting molded motor was tapped with ahammer several times; as a result, the outer molded portion was readilyremoved from the coil and the iron core.

As described above, exposing the inner molded portion before soakingfacilitated the decomposition of the molded motor.

EXAMPLE 29

A molded motor as shown in FIG. 2 was fabricated in the same way as inExample 27, except that polyethylene terephthalate having a heatdistortion temperature of 240° C was used as an insulator and thethickness of the outer molded portion was prescribed to be about 8 mm.The molded motor was soaked in the decomposing solution of Example 27for 24 hours. After being soaked, the inner molded portion wascompletely dissolved in the decomposing solution, and the inside of themolded stator became hollow. The resulting molded motor was tapped witha hammer several times; as a result, the outer molded portion wasreadily removed from the coil, the iron core, and the insulator.

EXAMPLE 30

The molded motor was soaked in the decomposing solution of Example 29for 24 hours in the same way as in Example 29, except that the outermolded portion was scratched with a chisel so as to partially expose theinner molded portion before soaking the molded motor.

Exposing the inner molded portion before soaking facilitated thedecomposition of the molded motor.

EXAMPLE 31

The molded motor was soaked in toluene as a decomposing solution for 24hours in the same way as in Example 27, except that the outer moldedportion was scratched with a chisel so as to partially expose the innermolded portion before soaking the molded motor After being soaked, mostof the inner molded portion was dissolved in the decomposing solution,and the inside of the molded stator became hollow. The resulting moldedstator was tapped with a hammer several times; as a result, the outermolded portion was readily removed from the coil and the iron core.

INDUSTRIAL APPLICABILITY

As described above, according to the present invention, (1) athermosetting composition which retains conventional outstandingcharacteristics such as hardness, mechanical strength, heat resistance,frame resistance, and chemical resistance and which can be readilydecomposed for disposal; (2) a molding compound using a thermosettingcomposition which retains conventional outstanding characteristics suchas hardness, mechanical strength, heat resistance, frame resistance, andchemical resistance and which can be readily decomposed for disposal;(3) a molded structure which has a molding compound using athermosetting composition and which can be readily decomposed fordisposal; (4) a method for conveniently and readily decomposing athermosetting composition, a molding compound, and a molded structureusing the thermosetting composition and the molding compound; and (5) amethod for recycling the molded structure; are provided.

We claim:
 1. A molded structure comprising a molded portion made of amolding compound, integrally molded containing at least metals,whereinat least part of the molding compound includes as a binder athermosetting composition containing a thermosetting resin and analiphatic polyester, decomposition of the thermosetting composition ispromoted by decomposition of the aliphatic polyester in a decomposingsolution containing from about 0.1 to about 50% by weight of at leastone base selected from the group consisting of alkali metal hydroxides,alkaline earth metal hydroxides, alkali metal oxides, alkaline earthmetal oxides, alkali metal alkoxides and alkaline earth metal alkoxides,and at least one solvent comprising water, methanol, ethanol or ethyleneglycol after the thermosetting composition is cured, and the metals andthe molding compound are separated.
 2. A molded structure comprising amolded portion made of a molding compound, integrally molded containingat least metals,wherein at least part of the molding compound includesas a binder a thermosetting composition containing an unsaturatedpolyester, an addition polymerizable monomer, and polycaprolactone, thethermosetting composition is decomposed in decomposing solutioncontaining a base and at least one solvent selected from the groupconsisting of water, methanol, ethanol, and ethylene glycol at atemperature lower than a boiling point of the decomposing solution afterbeing cured, and the metals and the molding compound are separated.
 3. Amolded structure comprising a molded portion made of a molding compound,integrally molded containing at least metals,wherein at least part ofthe molding compound includes as a binder a thermosetting compositioncontaining an unsaturated polyester, an addition polymerizable monomer,and polycaprolactone, the thermosetting composition is decomposed indecomposing solution containing a base and at least one solvent selectedfrom the group consisting of water, methanol, ethanol, and ethyleneglycol at a temperature lower than a boiling point of the decomposingsolution after being cured, and the metals and the molding compound areseparated, further comprising at least one aliphatic polyester selectedfrom the group consisting of polypropiolactone, polyglycolic acid,polylactic acid, polyethylene adipate, polybutylene adipate,polytetramethylene adipate, polyethylene succinate, polybutylenesuccinate, polycaprolactonediol, polycaprolactonetriol, andpoly(3-hydroxyalcanoate).
 4. A molded structure comprising a moldedportion made of a molding compound, integrally molded containing atleast metals,wherein at least part of the molding compound includes as abinder a thermosetting composition containing an unsaturated polyester,an addition polymerizable monomer, and polycaprolactone, thethermosetting composition is decomposed in decomposing solutioncontaining a base and at least one solvent selected from the groupconsisting of water, methanol, ethanol, and ethylene glycol at atemperature lower than a boiling point of the decomposing solution afterbeing cured, and the metals and the molding compound are separated,further comprising at least one aliphatic polyester selected from thegroup consisting of polypropiolactone, polyglycolic acid, polylacticacid, polyethylene adipate, polybutylene adipate, polytetramethyleneadipate, polyethylene succinate, polybutylene succinate,polycaprolactonediol, polycaprolactonetriol, andpoly(3-hydroxyalcanoate), wherein at least part of the aliphaticpolyester is dispersed in the molded portion as a filter in fiber form,needle form, or particle form.
 5. A molded structure according to claim1, wherein the metals are coils, and the structure is used for a motor.6. A molded structure according to claim 5, comprising a molded portionmade of a molding compound, integrally molded containing the coil, aninsulator, and an iron core,wherein a part of the insulator penetratesthe molded portion to be exposed to a surface of the molded portion. 7.A molded structure according to claim 6, wherein the insulator is madeof an aliphatic polyester.
 8. A molded structure comprising a moldedportion made of a molding compound, integrally molded containing atleast metals,wherein at least part of the molding compound contains as abinder a thermosetting composition containing an unsaturated polyester,styrene, polycaprolactone, and an aliphatic polyester, the aliphaticpolyester is at least one selected from the group consisting ofpolypropiolactone, polyglycolic acid, polylactic acid, polyethyleneadipate, polybutylene adipate, polytetramethylene adipate, polyethylenesuccinate, polybutylene succinate, polycaprolactonediol,polycaprolactonetriol, and poly(3-hydroxyalcanoate), the thermosettingcomposition is decomposed in a decomposing solution containing fromabout 0.1 to about 50% by weight of at least one base selected from thegroup consisting of alkali metal hydroxides, alkaline earth metalhydroxides, alkali metal oxides, alkali metal alkoxides and alkalineearth metal alkoxides, and at least one solvent selected from the groupconsisting of water, methanol, ethanol, and ethylene glycol at atemperature lower than a boiling point of the decomposing solution afterbeing cured, and the metals and the molding compound are separated.
 9. Amethod for decomposing a molded structure, comprising the step ofsoaking the molded structure in a decomposing solution containing fromabout 0.1 to about 50% by weight of at least one base selected from thegroup consisting of alkali metal hydroxides, alkaline earth metalhydroxides, alkali metal oxides, alkaline earth metal oxides, alkalimetal alkoxides and alkaline earth metal alkoxides, at least one solventselected from the group consisting of water, methanol, ethanol, andethylene glycol,wherein the molded structure includes a molded portionmade of a molding compound, integrally molded containing at leastmetals, and at least part of the molding compound includes as a binder athermosetting composition containing at least an aliphatic polyester anda thermosetting resin.
 10. A method for decomposing a molded structureaccording to claim 9, wherein the molded structure is soaked in thedecomposing solution at a temperature lower than a boiling point of thedecomposing solution.
 11. A method for decomposing a molded structureaccording to claim 9, wherein the decomposing solution further containsat least one solvent selected from the group consisting of acetone,2-butanone, dimethylformamide, dimethyl sulfoxide, dioxane,tetrahydrofuran, diethyl ether, diethylene glycol, diethylene glycolmonoester, diethylene glycol diester, dicarboxylic acid diester, methylacetate, ethyl acetate, benzene, toluene, and phenol.
 12. A method forrecycling a molded structure including a molded portion made of amolding compound, integrally molded containing at least metals,whereinat least part of the molding compound contains as a binder athermosetting composition containing at least an aliphatic polyester anda thermosetting resin, the method comprising the steps of:soaking themolded structure in a decomposing solution containing from about 0.1 toabout 50% by weight of at least one base selected from the groupconsisting of alkali metal hydroxides, alkaline earth metal hydroxides,alkali metal oxides, alkali earth metal oxides, alkali metal alkoxidesand alkaline earth metal alkoxides, and at least one solvent selectedfrom the group consisting of water, methanol, ethanol, and ethyleneglycol so as to chemically decompose the molded portion to a degree thata form of the molded portion cannot be maintained; and separating themetals from the decomposed molded portion and recovering the metals. 13.A method for recycling a molded structure according to claim 12, whereinthe molded structure is soaked in the decomposing solution at atemperature lower than a boiling point of the decomposing solution. 14.A method for recycling a molded structure according to claim 12, whereinthe metals are coils, and the structure is a motor.
 15. A moldedstructure according to claim 2, wherein the metals are coils, and thestructure is used for a motor.